Ford - Expedition 4wd - Workshop Manual - 2000 - 2000

Factory Workshop Manual Make Ford Model Expedition 4wd Engine and year V8-5.4L SOHC VIN L (2000) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 P0100 - P0104: Testing and Inspection P0102 For diagnosis of code P0102 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104, ( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 9 P0100 - P0104: Testing and Inspection P0103 For diagnosis of code P0103 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 P0105 - P0109: Testing and Inspection P0106 For diagnosis of code P0106 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 14 P0105 - P0109: Testing and Inspection P0107 For diagnosis of code P0107 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 15 P0105 - P0109: Testing and Inspection P0108 For diagnosis of code P0108 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109, ( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 16 P0105 - P0109: Testing and Inspection P0109 For diagnosis of code P0109 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 P0110 - P0114: Testing and Inspection P0112 For diagnosis of code P0112 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114, ( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 21 P0110 - P0114: Testing and Inspection P0113 For diagnosis of code P0113 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0117 P0115 - P0119: Testing and Inspection P0117 For diagnosis of code P0117 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119, ( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0117 > Page 26 P0115 - P0119: Testing and Inspection P0118 For diagnosis of code P0118 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 P0120 - P0124: Testing and Inspection P0121 For diagnosis of code P0121 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 31 P0120 - P0124: Testing and Inspection P0122 For diagnosis of code P0122 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124, ( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 32 P0120 - P0124: Testing and Inspection P0123 For diagnosis of code P0123 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 P0125 - P0129: Testing and Inspection P0125 For diagnosis of code P0125 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129, ( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 37 P0125 - P0129: Testing and Inspection P0127 For diagnosis of code P0127 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 P0130 - P0134: Testing and Inspection P0131 For diagnosis of code P0131 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134, ( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 42 P0130 - P0134: Testing and Inspection P0133 For diagnosis of code P0133 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 P0135 - P0139: Testing and Inspection P0135 For diagnosis of code P0135 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139, ( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 47 P0135 - P0139: Testing and Inspection P0136 For diagnosis of code P0136 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0140 - P0144, ( P0141 P0142 P0143 0140 0141 0142 0143 0144 ) > System Information > System Diagnosis P0140 - P0144: Testing and Inspection For diagnosis of code P0141 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 P0150 - P0154: Testing and Inspection P0151 For diagnosis of code P0151 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154, ( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 55 P0150 - P0154: Testing and Inspection P0153 For diagnosis of code P0153 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 P0155 - P0159: Testing and Inspection P0155 For diagnosis of code P0155 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159, ( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 60 P0155 - P0159: Testing and Inspection P0156 For diagnosis of code P0156 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0160 - P0164, ( P0161 P0162 P0163 0160 0161 0162 0163 0164 ) > System Information > System Diagnosis P0160 - P0164: Testing and Inspection For diagnosis of code P0161 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 P0170 - P0174: Testing and Inspection P0171 For diagnosis of code P0171 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 68 P0170 - P0174: Testing and Inspection P0172 For diagnosis of code P0172 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174, ( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 69 P0170 - P0174: Testing and Inspection P0174 For diagnosis of code P0174 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179, ( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175 P0175 - P0179: Testing and Inspection P0175 For diagnosis of code P0175 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179, ( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175 > Page 74 P0175 - P0179: Testing and Inspection P0176 For diagnosis of code P0176 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 P0180 - P0184: Testing and Inspection P0180 For diagnosis of code P0180 refer to chart P0102 - P0180 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 79 P0180 - P0184: Testing and Inspection P0181 For diagnosis of code P0181 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 80 P0180 - P0184: Testing and Inspection P0182 For diagnosis of code P0182 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184, ( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 81 P0180 - P0184: Testing and Inspection P0183 For diagnosis of code P0183 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 P0190 - P0194: Testing and Inspection P0190 For diagnosis of code P0190 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 86 P0190 - P0194: Testing and Inspection P0191 For diagnosis of code P0191 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 87 P0190 - P0194: Testing and Inspection P0192 For diagnosis of code P0192 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194, ( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 88 P0190 - P0194: Testing and Inspection P0193 For diagnosis of code P0193 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 P0200 - P0204: Testing and Inspection P0201 For diagnosis of code P0201 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 94 P0200 - P0204: Testing and Inspection P0202 For diagnosis of code P0202 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 95 P0200 - P0204: Testing and Inspection P0203 For diagnosis of code P0203 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204, ( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 96 P0200 - P0204: Testing and Inspection P0204 For diagnosis of code P0204 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 P0205 - P0209: Testing and Inspection P0205 For diagnosis of code P0205 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 101 P0205 - P0209: Testing and Inspection P0206 For diagnosis of code P0206 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 102 P0205 - P0209: Testing and Inspection P0207 For diagnosis of code P0207 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 103 P0205 - P0209: Testing and Inspection P0208 For diagnosis of code P0208 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209, ( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 104 P0205 - P0209: Testing and Inspection P0209 For diagnosis of code P0209 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 P0210 - P0214: Testing and Inspection P0210 For diagnosis of code P0210 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 109 P0210 - P0214: Testing and Inspection P0211 For diagnosis of code P0211 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214, ( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 110 P0210 - P0214: Testing and Inspection P0212 For diagnosis of code P0212 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0215 - P0219, ( P0216 P0217 P0218 0215 0216 0217 0218 0219 ) > System Information > System Diagnosis P0215 - P0219: Testing and Inspection For diagnosis of code P0217 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 P0230 - P0234: Testing and Inspection P0230 For diagnosis of code P0230 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 118 P0230 - P0234: Testing and Inspection P0231 For diagnosis of code P0231 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234, ( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 119 P0230 - P0234: Testing and Inspection P0232 For diagnosis of code P0232 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 P0300 - P0304: Testing and Inspection P0300 For diagnosis of code P0300 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 125 P0300 - P0304: Testing and Inspection P0301 For diagnosis of code P0301 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 126 P0300 - P0304: Testing and Inspection P0302 For diagnosis of code P0302 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 127 P0300 - P0304: Testing and Inspection P0303 For diagnosis of code P0303 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304, ( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 128 P0300 - P0304: Testing and Inspection P0304 For diagnosis of code P0304 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 P0305 - P0309: Testing and Inspection P0305 For diagnosis of code P0305 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 133 P0305 - P0309: Testing and Inspection P0306 For diagnosis of code P0306 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 134 P0305 - P0309: Testing and Inspection P0307 For diagnosis of code P0307 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 135 P0305 - P0309: Testing and Inspection P0308 For diagnosis of code P0308 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309, ( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 136 P0305 - P0309: Testing and Inspection P0309 For diagnosis of code P0309 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0310 - P0314, ( P0311 P0312 P0313 0310 0311 0312 0313 0314 ) > System Information > System Diagnosis P0310 - P0314: Testing and Inspection For diagnosis of code P0310 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0320 - P0324, ( P0321 P0322 P0323 0320 0321 0322 0323 0324 ) > System Information > System Diagnosis P0320 - P0324: Testing and Inspection For diagnosis of code P0320 refer to chart P0181 - P0325 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 P0325 - P0329: Testing and Inspection P0325 For diagnosis of code P0325 refer to charts P0181 - P0325 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 147 P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329, ( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 148 P0325 - P0329: Testing and Inspection P0326 For diagnosis of code P0326 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 P0330 - P0334: Testing and Inspection P0330 For diagnosis of code P0330 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334, ( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 > Page 153 P0330 - P0334: Testing and Inspection P0331 For diagnosis of code P0331 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0340 - P0344, ( P0341 P0342 P0343 0340 0341 0342 0343 0344 ) > System Information > System Diagnosis P0340 - P0344: Testing and Inspection For diagnosis of code P0340 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 P0350 - P0354: Testing and Inspection P0350 For diagnosis of code P0350 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 161 P0350 - P0354: Testing and Inspection P0351 For diagnosis of code P0351 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 162 P0350 - P0354: Testing and Inspection P0352 For diagnosis of code P0352 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 163 P0350 - P0354: Testing and Inspection P0353 For diagnosis of code P0353 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354, ( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 164 P0350 - P0354: Testing and Inspection P0354 For diagnosis of code P0354 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 P0355 - P0359: Testing and Inspection P0355 For diagnosis of code P0355 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 169 P0355 - P0359: Testing and Inspection P0356 For diagnosis of code P0356 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 170 P0355 - P0359: Testing and Inspection P0357 For diagnosis of code P0357 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 171 P0355 - P0359: Testing and Inspection P0358 For diagnosis of code P0358 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359, ( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 172 P0355 - P0359: Testing and Inspection P0359 For diagnosis of code P0359 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0360 - P0364, ( P0361 P0362 P0363 0360 0361 0362 0363 0364 ) > System Information > System Diagnosis P0360 - P0364: Testing and Inspection For diagnosis of code P0360 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0401 P0400 - P0404: Testing and Inspection P0401 For diagnosis of code P0401 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404, ( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0401 > Page 181 P0400 - P0404: Testing and Inspection P0402 For diagnosis of code P0402 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 P0410 - P0414: Testing and Inspection P0411 For diagnosis of code P0411 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414, ( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 > Page 186 P0410 - P0414: Testing and Inspection P0412 For diagnosis of code P0412 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0420 - P0424, ( P0421 P0422 P0423 0420 0421 0422 0423 0424 ) > System Information > System Diagnosis P0420 - P0424: Testing and Inspection For diagnosis of code P0420 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0430 - P0434, ( P0431 P0432 P0433 0430 0431 0432 0433 0434 ) > System Information > System Diagnosis P0430 - P0434: Testing and Inspection For diagnosis of code P0430 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444, ( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 P0440 - P0444: Testing and Inspection P0442 For diagnosis of code P0442 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444, ( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 > Page 197 P0440 - P0444: Testing and Inspection P0443 For diagnosis of code P0443 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 P0450 - P0454: Testing and Inspection P0451 For diagnosis of code P0451 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 202 P0450 - P0454: Testing and Inspection P0452 For diagnosis of code P0452 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454, ( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 203 P0450 - P0454: Testing and Inspection P0453 For diagnosis of code P0453 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 P0455 - P0459: Testing and Inspection P0455 For diagnosis of code P0455 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459, ( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 208 P0455 - P0459: Testing and Inspection P0457 For diagnosis of code P0457 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 P0460 - P0464: Testing and Inspection P0460 For diagnosis of code P0460 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464, ( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 213 P0460 - P0464: Testing and Inspection P0461 For diagnosis of code P0461 refer to chart P0326 - P0461 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 P0500 - P0504: Testing and Inspection P0500 For diagnosis of code P0500 refer to system experiencing problems Engine Controls P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 219 Inspection Transfer Case B1820-B2106 / C1107 / P0500-P1836 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Windshield Wiper/Washer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 220 Part 3 Of 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Windshield Wiper/Washer diagnostic information, See: Wiper and Washer Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 221 P0500 - P0504: Testing and Inspection P0501 For diagnosis of code P0501 refer to chart P0500 - P0813 NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 222 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 223 P0500 - P0504: Testing and Inspection P0503 For diagnosis of code P0503 refer to chart P0500 - P0813 NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 224 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509, ( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis P0505 - P0509: Testing and Inspection For diagnosis of code P0505 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 P0550 - P0554: Testing and Inspection P0552 For diagnosis of code P0552 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554, ( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 > Page 232 P0550 - P0554: Testing and Inspection P0553 For diagnosis of code P0553 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 P0600 - P0604: Testing and Inspection P0602 For diagnosis of code P0602 refer to chart P0500 - P0813 NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to Flash VID Block procedure, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 238 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604, ( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 239 P0600 - P0604: Testing and Inspection P0603 For diagnosis of code P0603 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609, ( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis P0605 - P0609: Testing and Inspection For diagnosis of code P0605 refer to chart P0500 - P0813 NOTE 14: Be sure to check for aftermarket performance products before replacing PCM. (If replacement is necessary refer to Flash Electrically Eraseable Programmable Read Only Memory Flash EEPROM.) See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609, ( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis > Page 243 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 P0700 - P0704: Testing and Inspection P0703 For diagnosis of code P0703 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704, ( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 > Page 249 P0700 - P0704: Testing and Inspection P0704 For diagnosis of code P0704 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 P0705 - P0709: Testing and Inspection P0705 For diagnosis of code P0705 refer to chart P0122-P1783 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 254 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 255 P0705 - P0709: Testing and Inspection P0708 For diagnosis of code P0708 refer to chart P0102-P1703 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709, ( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 256 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 P0710 - P0714: Testing and Inspection P0712 For diagnosis of code P0712 refer to chart P0122-P1783 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 261 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 262 P0710 - P0714: Testing and Inspection P0713 For diagnosis of code P0713 refer to chart P0123-P1744 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714, ( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 263 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719, ( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis > P0715 P0715 - P0719: Testing and Inspection P0715 For diagnosis of code P0715 refer to chart P0715-P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719, ( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis > P0715 > Page 268 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719, ( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis > P0715 > Page 269 P0715 - P0719: Testing and Inspection P0717 For diagnosis of code P0717 refer to chart P0715-P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719, ( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis > P0715 > Page 270 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719, ( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis > P0715 > Page 271 P0715 - P0719: Testing and Inspection P0718 For diagnosis of code P0718 refer to chart P0715-P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719, ( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis > P0715 > Page 272 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission P0720 - P0724: Testing and Inspection Manual Transmission For diagnosis of code P072x refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 277 Note: "x" = any number 0 thru 9 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 278 P0720 - P0724: Testing and Inspection Automatic Transmission P0720 For diagnosis of code P0720 refer to chart P0715-P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 279 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P0721 For diagnosis of code P0721 refer to chart Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 280 P0715-P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P0722 ( P 0722 ) For diagnosis of code P0722 refer to chart Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 281 P0715-P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission > Page 282 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0725 - P0729, ( P0726 P0727 P0728 0725 0726 0727 0728 0729 ) > System Information > System Diagnosis P0725 - P0729: Testing and Inspection For diagnosis of code P072x refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Note: "x" = any number 0 thru 9 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 P0740 - P0744: Testing and Inspection P0741 For diagnosis of code P0741 refer to chart P0123-P1744 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 290 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744, ( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 291 P0740 - P0744: Testing and Inspection P0743 For diagnosis of code P0743 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis P0750 - P0754: Testing and Inspection For diagnosis of code P0750 refer to chart P0705-P1754 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754, ( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis > Page 295 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis P0755 - P0759: Testing and Inspection For diagnosis of code P0755 refer to chart P0705-P1754 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759, ( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > Page 299 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 P0780 - P0784: Testing and Inspection P0781 For diagnosis of code P0781 refer to chart P0236-P1711 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 > Page 304 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 > Page 305 P0780 - P0784: Testing and Inspection P0782 For diagnosis of code P0782 refer to chart P0123-P1744 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 > Page 306 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 > Page 307 P0780 - P0784: Testing and Inspection P0783 For diagnosis of code P0783 refer to chart P0102-P1703 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0780 - P0784, ( P0781 P0782 P0783 0780 0781 0782 0783 0784 ) > System Information > System Diagnosis > P0781 > Page 308 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0810 - P0814, ( P0811 P0812 P0813 0810 0811 0812 0813 0814 ) > System Information > System Diagnosis P0810 - P0814: Testing and Inspection For diagnosis of code P0812 refer to chart P0500 - P0813 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 P1000 - P1004: Testing and Inspection P1000 For diagnosis of code P1000 refer to chart P0815 - P1169 NOTE 1: DTC 1000 is ignored in KOEO and KOER Self-Test. Disregard the DTC P1000 and continue as directed. If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004, ( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 > Page 318 P1000 - P1004: Testing and Inspection P1001 For diagnosis of code P1001 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 P1100 - P1104: Testing and Inspection P1100 For diagnosis of code P1100 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104, ( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 > Page 324 P1100 - P1104: Testing and Inspection P1101 For diagnosis of code P1101 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114, ( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis P1110 - P1114: Testing and Inspection For diagnosis of code P1112 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1116 P1115 - P1119: Testing and Inspection P1116 For diagnosis of code P1116 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119, ( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1116 > Page 332 P1115 - P1119: Testing and Inspection P1117 For diagnosis of code P1117 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 P1120 - P1124: Testing and Inspection P1120 For diagnosis of code P1120 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 337 P1120 - P1124: Testing and Inspection P1121 For diagnosis of code P1121 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124, ( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 338 P1120 - P1124: Testing and Inspection P1124 For diagnosis of code P1124 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 P1125 - P1129: Testing and Inspection P1125 For diagnosis of code P1125 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 343 P1125 - P1129: Testing and Inspection P1127 For diagnosis of code P1127 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 344 P1125 - P1129: Testing and Inspection P1128 For diagnosis of code P1128 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129, ( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 345 P1125 - P1129: Testing and Inspection P1129 For diagnosis of code P1129 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 P1130 - P1134: Testing and Inspection P1130 For diagnosis of code P1130 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 350 P1130 - P1134: Testing and Inspection P1131 For diagnosis of code P1131 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134, ( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 351 P1130 - P1134: Testing and Inspection P1132 For diagnosis of code P1132 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139, ( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 P1135 - P1139: Testing and Inspection P1137 For diagnosis of code P1137 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139, ( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 > Page 356 P1135 - P1139: Testing and Inspection P1138 For diagnosis of code P1138 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 P1150 - P1154: Testing and Inspection P1150 For diagnosis of code P1150 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 361 P1150 - P1154: Testing and Inspection P1151 For diagnosis of code P1151 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154, ( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 362 P1150 - P1154: Testing and Inspection P1152 For diagnosis of code P1152 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 P1155 - P1159: Testing and Inspection P1157 For diagnosis of code P1157 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159, ( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 > Page 367 P1155 - P1159: Testing and Inspection P1158 For diagnosis of code P1158 refer to chart P0815 - P1169 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1195 - P1199, ( P1196 P1197 P1198 1195 1196 1197 1198 1199 ) > System Information > System Diagnosis P1195 - P1199: Testing and Inspection For diagnosis of code P1197 refer to chart Part 2 Of 2 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 P1230 - P1234: Testing and Inspection P1232 For diagnosis of code P1232 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 376 P1230 - P1234: Testing and Inspection P1233 For diagnosis of code P1233 refer to chart P1180 - P1460 NOTE 10: Perform Rear Electronics Module (REM) self-test/diagnostics. If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234, ( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 377 P1230 - P1234: Testing and Inspection P1234 For diagnosis of code P1234 refer to chart P1180 - P1460 NOTE 10: Perform Rear Electronics Module (REM) self-test/diagnostics. If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 P1235 - P1239: Testing and Inspection P1235 For diagnosis of code P1235 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 382 P1235 - P1239: Testing and Inspection P1236 For diagnosis of code P1236 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 383 P1235 - P1239: Testing and Inspection P1237 For diagnosis of code P1237 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239, ( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 384 P1235 - P1239: Testing and Inspection P1238 For diagnosis of code P1238 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1240 - P1244, ( P1241 P1242 P1243 1240 1241 1242 1243 1244 ) > System Information > System Diagnosis P1240 - P1244: Testing and Inspection For diagnosis of code P1244 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 P1245 - P1249: Testing and Inspection P1245 For diagnosis of code P1245 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249, ( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 > Page 392 P1245 - P1249: Testing and Inspection P1246 For diagnosis of code P1246 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264, ( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis P1260 - P1264: Testing and Inspection For diagnosis of code P1260 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274, ( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis P1270 - P1274: Testing and Inspection For diagnosis of code P1270 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 P1285 - P1289: Testing and Inspection P1285 For diagnosis of code P1285 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 403 P1285 - P1289: Testing and Inspection P1288 For diagnosis of code P1288 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289, ( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 404 P1285 - P1289: Testing and Inspection P1289 For diagnosis of code P1289 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1290 - P1294, ( P1291 P1292 P1293 1290 1291 1292 1293 1294 ) > System Information > System Diagnosis P1290 - P1294: Testing and Inspection For diagnosis of code P1290 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1295 - P1299, ( P1296 P1297 P1298 1295 1296 1297 1298 1299 ) > System Information > System Diagnosis P1295 - P1299: Testing and Inspection For diagnosis of code P1299 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1305 - P1309, ( P1306 P1307 P1308 1305 1306 1307 1308 1309 ) > System Information > System Diagnosis P1305 - P1309: Testing and Inspection For diagnosis of code P1309 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 P1380 - P1384: Testing and Inspection P1380 For diagnosis of code P1380 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 419 P1380 - P1384: Testing and Inspection P1381 For diagnosis of code P1381 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384, ( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 420 P1380 - P1384: Testing and Inspection P1383 For diagnosis of code P1383 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404, ( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 P1400 - P1404: Testing and Inspection P1400 For diagnosis of code P1400 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404, ( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 > Page 426 P1400 - P1404: Testing and Inspection P1401 For diagnosis of code P1401 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 P1405 - P1409: Testing and Inspection P1405 For diagnosis of code P1405 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 431 P1405 - P1409: Testing and Inspection P1406 For diagnosis of code P1406 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 432 P1405 - P1409: Testing and Inspection P1408 For diagnosis of code P1408 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409, ( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 433 P1405 - P1409: Testing and Inspection P1409 For diagnosis of code P1409 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414, ( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 P1410 - P1414: Testing and Inspection P1413 For diagnosis of code P1413 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414, ( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 > Page 438 P1410 - P1414: Testing and Inspection P1414 For diagnosis of code P1414 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1440 - P1444, ( P1441 P1442 P1443 1440 1441 1442 1443 1444 ) > System Information > System Diagnosis P1440 - P1444: Testing and Inspection For diagnosis of code P1443 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 P1450 - P1454: Testing and Inspection P1450 For diagnosis of code P1450 refer to the system experiencing the problem. Computers and Control Systems Refer to Pinpoint Test HX18. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/Tests HX: Evaporative Emission (EVAP) Monitor and System If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Evaporative Emissions System If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454, ( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 446 P1450 - P1454: Testing and Inspection P1451 For diagnosis of code P1451 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 P1460 - P1464: Testing and Inspection P1460 For diagnosis of code P1460 refer to chart P1180 - P1460 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 451 P1460 - P1464: Testing and Inspection P1461 For diagnosis of code P1461 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 452 P1460 - P1464: Testing and Inspection P1462 For diagnosis of code P1462 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 453 P1460 - P1464: Testing and Inspection P1463 For diagnosis of code P1463 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464, ( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 454 P1460 - P1464: Testing and Inspection P1464 For diagnosis of code P1464 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1465 - P1469, ( P1466 P1467 P1468 1465 1466 1467 1468 1469 ) > System Information > System Diagnosis P1465 - P1469: Testing and Inspection For diagnosis of code P1469 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1470 - P1474, ( P1471 P1472 P1473 1470 1471 1472 1473 1474 ) > System Information > System Diagnosis P1470 - P1474: Testing and Inspection For diagnosis of code P1474 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479, ( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis P1475 - P1479: Testing and Inspection For diagnosis of code P1479 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 P1500 - P1504: Testing and Inspection P1500 For diagnosis of code P1500 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 469 P1500 - P1504: Testing and Inspection P1501 For diagnosis of code P1501 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 470 P1500 - P1504: Testing and Inspection P1502 For diagnosis of code P1502 refer to chart P1461 - P1641 NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 471 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504, ( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 472 P1500 - P1504: Testing and Inspection P1504 For diagnosis of code P1504 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 P1505 - P1509: Testing and Inspection P1506 For diagnosis of code P1506 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509, ( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 > Page 477 P1505 - P1509: Testing and Inspection P1507 For diagnosis of code P1507 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1510 - P1514, ( P1511 P1512 P1513 1510 1511 1512 1513 1514 ) > System Information > System Diagnosis > P1512 P1510 - P1514: Testing and Inspection P1512 For diagnosis of code P1512 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1510 - P1514, ( P1511 P1512 P1513 1510 1511 1512 1513 1514 ) > System Information > System Diagnosis > P1512 > Page 482 P1510 - P1514: Testing and Inspection P1513 For diagnosis of code P1513 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 P1515 - P1519: Testing and Inspection P1516 For diagnosis of code P1516 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 487 P1515 - P1519: Testing and Inspection P1517 For diagnosis of code P1517 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 488 P1515 - P1519: Testing and Inspection P1518 For diagnosis of code P1518 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519, ( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 489 P1515 - P1519: Testing and Inspection P1519 For diagnosis of code P1519 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1520 - P1524, ( P1521 P1522 P1523 1520 1521 1522 1523 1524 ) > System Information > System Diagnosis P1520 - P1524: Testing and Inspection For diagnosis of code P1520 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1535 - P1539, ( P1536 P1537 P1538 1535 1536 1537 1538 1539 ) > System Information > System Diagnosis > P1537 P1535 - P1539: Testing and Inspection P1537 For diagnosis of code P1537 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1535 - P1539, ( P1536 P1537 P1538 1535 1536 1537 1538 1539 ) > System Information > System Diagnosis > P1537 > Page 497 P1535 - P1539: Testing and Inspection P1538 For diagnosis of code P1538 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1545 - P1549, ( P1546 P1547 P1548 1545 1546 1547 1548 1549 ) > System Information > System Diagnosis P1545 - P1549: Testing and Inspection For diagnosis of code P1549 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1550 - P1554, ( P1551 P1552 P1553 1550 1551 1552 1553 1554 ) > System Information > System Diagnosis P1550 - P1554: Testing and Inspection For diagnosis of code P1550 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1605 - P1609, ( P1606 P1607 P1608 1605 1606 1607 1608 1609 ) > System Information > System Diagnosis P1605 - P1609: Testing and Inspection For diagnosis of code P1605 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1630 - P1634, ( P1631 P1632 P1633 1630 1631 1632 1633 1634 ) > System Information > System Diagnosis P1630 - P1634: Testing and Inspection For diagnosis of code P1633 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 P1635 - P1639: Testing and Inspection P1635 For diagnosis of code P1635 refer to chart P1461 - P1641 NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to Flash VID Block procedure, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 515 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 516 P1635 - P1639: Testing and Inspection P1636 For diagnosis of code P1636 refer to chart P1461 - P1641 NOTE 18: DTC 1636 indicates the PCM has lost communication withthe Inductive Signature Chip. Replace the PCM (refer to Flash Electrically Eraseable Programmable Read Only Memory - Flash EEPROM). See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 517 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 518 P1635 - P1639: Testing and Inspection P1639 For diagnosis of code P1639 refer to chart P1461 - P1641 NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to Flash VID Block procedure, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639, ( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 519 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1640 - P1644, ( P1641 P1642 P1643 1640 1641 1642 1643 1644 ) > System Information > System Diagnosis P1640 - P1644: Testing and Inspection For diagnosis of code P1641 refer to chart P1461 - P1641 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 P1650 - P1654: Testing and Inspection P1650 For diagnosis of code P1650 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654, ( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 > Page 527 P1650 - P1654: Testing and Inspection P1651 For diagnosis of code P1651 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 P1700 - P1704: Testing and Inspection P1702 For diagnosis of code P1702 refer to chart P0102-P1703 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 533 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 534 P1700 - P1704: Testing and Inspection P1703 For diagnosis of code P1703 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 535 P1700 - P1704: Testing and Inspection P1704 For diagnosis of code P1704 refer to chart P0715-P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704, ( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1702 > Page 536 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 P1705 - P1709: Testing and Inspection P1705 Manual Transmission For diagnosis of code P1705 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Automatic Transmission For diagnosis of code P1705 refer to chart Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 541 P0122-P1783 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 542 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709, ( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 543 P1705 - P1709: Testing and Inspection P1709 For diagnosis of code P1709 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1713 P1710 - P1714: Testing and Inspection P1713 For diagnosis of code P1713 refer to chart P1713-P1747 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1713 > Page 548 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1713 > Page 549 P1710 - P1714: Testing and Inspection P1714 For diagnosis of code P1714 refer to chart P0705-P1754 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714, ( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1713 > Page 550 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 P1715 - P1719: Testing and Inspection P1715 For diagnosis of code P1715 refer to chart P0705-P1754 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 555 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 556 P1715 - P1719: Testing and Inspection P1718 For diagnosis of code P1718 refer to chart P0715-P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719, ( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 557 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1725 - P1729, ( P1726 P1727 P1728 1725 1726 1727 1728 1729 ) > System Information > System Diagnosis P1725 - P1729: Testing and Inspection For diagnosis of code P1729 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 P1740 - P1744: Testing and Inspection P1740 For diagnosis of code P1740 refer to chart P0705-P1754 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 565 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 566 P1740 - P1744: Testing and Inspection P1744 For diagnosis of code P1744 refer to chart P0123-P1744 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744, ( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > P1740 > Page 567 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 P1745 - P1749: Testing and Inspection P1746 For diagnosis of code P1746 refer to chart P1713-P1747 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 572 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 573 P1745 - P1749: Testing and Inspection P1747 For diagnosis of code P1747 refer to chart P1713-P1747 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749, ( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 574 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1750 - P1754, ( P1751 P1752 P1753 1750 1751 1752 1753 1754 ) > System Information > System Diagnosis P1750 - P1754: Testing and Inspection For diagnosis of code P1754 refer to chart P0705-P1754 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1750 - P1754, ( P1751 P1752 P1753 1750 1751 1752 1753 1754 ) > System Information > System Diagnosis > Page 578 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1760 - P1764, ( P1761 P1762 P1763 1760 1761 1762 1763 1764 ) > System Information > System Diagnosis P1760 - P1764: Testing and Inspection For diagnosis of code P1760 refer to chart P0715-P1781 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1760 - P1764, ( P1761 P1762 P1763 1760 1761 1762 1763 1764 ) > System Information > System Diagnosis > Page 582 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 P1780 - P1784: Testing and Inspection P1780 For diagnosis of code P1780 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 587 P1780 - P1784: Testing and Inspection P1781 For diagnosis of code P1781 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 588 P1780 - P1784: Testing and Inspection P1783 For diagnosis of code P1783 refer to chart P0122-P1783 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784, ( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 589 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1800 - P1804, ( P1801 P1802 P1803 1800 1801 1802 1803 1804 ) > System Information > System Diagnosis P1800 - P1804: Testing and Inspection For diagnosis of code P1804 refer to chart Part 2 Of 2 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1805 - P1809, ( P1806 P1807 P1808 1805 1806 1807 1808 1809 ) > System Information > System Diagnosis > P1806 P1805 - P1809: Testing and Inspection P1806 For diagnosis of code P1806 refer to chart Part 2 Of 2 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1805 - P1809, ( P1806 P1807 P1808 1805 1806 1807 1808 1809 ) > System Information > System Diagnosis > P1806 > Page 598 P1805 - P1809: Testing and Inspection P1807 For diagnosis of code P1807 refer to chart C1770-C1917 / P1807-P1808 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Suspension Control diagnostic information, See: Steering and Suspension/Suspension/Suspension Control ( Automatic - Electronic )/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1805 - P1809, ( P1806 P1807 P1808 1805 1806 1807 1808 1809 ) > System Information > System Diagnosis > P1806 > Page 599 P1805 - P1809: Testing and Inspection P1808 For diagnosis of code P1808 refer to chart C1770-C1917 / P1807-P1808 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Suspension Control diagnostic information, See: Steering and Suspension/Suspension/Suspension Control ( Automatic - Electronic )/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1810 - P1814, ( P1811 P1812 P1813 1810 1811 1812 1813 1814 ) > System Information > System Diagnosis P1810 - P1814: Testing and Inspection For diagnosis of code P1812 refer to chart B1820-B2106 / C1107 / P0500-P1836 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1815 - P1819, ( P1816 P1817 P1818 1815 1816 1817 1818 1819 ) > System Information > System Diagnosis P1815 - P1819: Testing and Inspection For diagnosis of code P1815 refer to chart B1820-B2106 / C1107 / P0500-P1836 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1820 - P1824, ( P1821 P1822 P1823 1820 1821 1822 1823 1824 ) > System Information > System Diagnosis > P1820 P1820 - P1824: Testing and Inspection P1820 For diagnosis of code P1820 refer to chart B1820-B2106 / C1107 / P0500-P1836 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1820 - P1824, ( P1821 P1822 P1823 1820 1821 1822 1823 1824 ) > System Information > System Diagnosis > P1820 > Page 610 P1820 - P1824: Testing and Inspection P1822 For diagnosis of code P1822 refer to chart B1820-B2106 / C1107 / P0500-P1836 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1820 - P1824, ( P1821 P1822 P1823 1820 1821 1822 1823 1824 ) > System Information > System Diagnosis > P1820 > Page 611 P1820 - P1824: Testing and Inspection P1824 For diagnosis of code P1824 refer to chart B1820-B2106 / C1107 / P0500-P1836 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1825 - P1829, ( P1826 P1827 P1828 1825 1826 1827 1828 1829 ) > System Information > System Diagnosis > P1826 P1825 - P1829: Testing and Inspection P1826 For diagnosis of code P1826 refer to chart B1820-B2106 / C1107 / P0500-P1836 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1825 - P1829, ( P1826 P1827 P1828 1825 1826 1827 1828 1829 ) > System Information > System Diagnosis > P1826 > Page 616 P1825 - P1829: Testing and Inspection P1828 For diagnosis of code P1828 refer to chart B1820-B2106 / C1107 / P0500-P1836 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1830 - P1834, ( P1831 P1832 P1833 1830 1831 1832 1833 1834 ) > System Information > System Diagnosis P1830 - P1834: Testing and Inspection For diagnosis of code P1830 refer to chart B1820-B2106 / C1107 / P0500-P1836 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1835 - P1839, ( P1836 P1837 P1838 1835 1836 1837 1838 1839 ) > System Information > System Diagnosis > P1836 P1835 - P1839: Testing and Inspection P1836 For diagnosis of code P1836 refer to chart B1820-B2106 / C1107 / P0500-P1836 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1835 - P1839, ( P1836 P1837 P1838 1835 1836 1837 1838 1839 ) > System Information > System Diagnosis > P1836 > Page 624 P1835 - P1839: Testing and Inspection P1837 For diagnosis of code P1837 refer to chart P1837-P1893 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1835 - P1839, ( P1836 P1837 P1838 1835 1836 1837 1838 1839 ) > System Information > System Diagnosis > P1836 > Page 625 P1835 - P1839: Testing and Inspection P1838 For diagnosis of code P1838 refer to chart P1837-P1893 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1845 - P1849, ( P1846 P1847 P1848 1845 1846 1847 1848 1849 ) > System Information > System Diagnosis P1845 - P1849: Testing and Inspection For diagnosis of code P1846 refer to chart P1837-P1893 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1850 - P1854, ( P1851 P1852 P1853 1850 1851 1852 1853 1854 ) > System Information > System Diagnosis > P1850 P1850 - P1854: Testing and Inspection P1850 For diagnosis of code P1850 refer to chart P1837-P1893 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1850 - P1854, ( P1851 P1852 P1853 1850 1851 1852 1853 1854 ) > System Information > System Diagnosis > P1850 > Page 633 P1850 - P1854: Testing and Inspection P1854 For diagnosis of code P1854 refer to chart P1837-P1893 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1855 - P1859, ( P1856 P1857 P1858 1855 1856 1857 1858 1859 ) > System Information > System Diagnosis P1855 - P1859: Testing and Inspection For diagnosis of code P1858 refer to chart P1837-P1893 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1865 - P1869, ( P1866 P1867 P1868 1865 1866 1867 1868 1869 ) > System Information > System Diagnosis > P1866 P1865 - P1869: Testing and Inspection P1866 For diagnosis of code P1866 refer to chart P1837-P1893 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1865 - P1869, ( P1866 P1867 P1868 1865 1866 1867 1868 1869 ) > System Information > System Diagnosis > P1866 > Page 641 P1865 - P1869: Testing and Inspection P1867 For diagnosis of code P1867 refer to chart P1837-P1893 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1870 - P1874, ( P1871 P1872 P1873 1870 1871 1872 1873 1874 ) > System Information > System Diagnosis P1870 - P1874: Testing and Inspection For diagnosis of code P1874 refer to chart P1837-P1893 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1875 - P1879, ( P1876 P1877 P1878 1875 1876 1877 1878 1879 ) > System Information > System Diagnosis P1875 - P1879: Testing and Inspection For diagnosis of code P1875 refer to chart P1837-P1893 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1890 - P1894, ( P1891 P1892 P1893 1890 1891 1892 1893 1894 ) > System Information > System Diagnosis > P1891 P1890 - P1894: Testing and Inspection P1891 For diagnosis of code P1891 refer to chart P1837-P1893 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1890 - P1894, ( P1891 P1892 P1893 1890 1891 1892 1893 1894 ) > System Information > System Diagnosis > P1891 > Page 652 P1890 - P1894: Testing and Inspection P1892 For diagnosis of code P1892 refer to chart P1837-P1893 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1890 - P1894, ( P1891 P1892 P1893 1890 1891 1892 1893 1894 ) > System Information > System Diagnosis > P1891 > Page 653 P1890 - P1894: Testing and Inspection P1893 For diagnosis of code P1893 refer to chart P1837-P1893 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Transfer Case, follow this link: See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904, ( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis P1900 - P1904: Testing and Inspection For diagnosis of code P1900 refer to chart P1650 - Uxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 664 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 665 Accessory Delay Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Passive Anti-Theft System Transceiver Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Passive Anti-Theft System Transceiver Module > Page 670 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Passive Anti-Theft System Transceiver Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Passive Anti-Theft System Transceiver Module > Page 673 Alarm Module: Diagrams Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications Multifunction Electronic Control Modules: Specifications Remote Anti-Theft Personality (RAP) Module Nuts 7 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications > Page 677 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 680 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 681 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 682 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 683 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 684 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 685 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 686 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 687 Multifunction Electronic Control Modules: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 688 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 689 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 690 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 691 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 692 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 693 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 694 Multifunction Electronic Control Modules: Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 695 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 696 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 697 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 59-1 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 698 Diagram 59-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 699 Diagram 59-3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 700 Diagram 59-4 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 701 Diagram 59-5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 702 Multifunction Electronic Control Modules: Service Precautions CAUTION: ^ Prior to removal of module, it is necessary to upload module configuration information to scan tool. This information needs to be downloaded into the new module once installed. For additional information; refer to Module Communications Network. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. ^ Once the new module is installed it is necessary to download the module configuration information from the scan tool into the new module. For additional information; refer to Module Communications Network. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > GEM Feature Matrix Multifunction Electronic Control Modules: Description and Operation GEM Feature Matrix Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > GEM Feature Matrix > Page 705 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > GEM Feature Matrix > Page 706 Multifunction Electronic Control Modules: Description and Operation Module Controlled Functions Module Controlled Functions The multi function modules consist of the following: ^ Generic Electronic Module (GEM) The generic electronic module (GEM) constantly monitors its subsystems for concerns. If a concern is found in one of the subsystems, the GEM will record the concern in the form of a Diagnostic Trouble Code (DTC). The ignition switch position is very important to the GEM function. Often times, erratic or unexpected GEM function can be traced to problems with these GEM inputs. The GEM controls the following features: ^ Wipers/washers (front/rear). ^ Warning chimes. ^ Battery saver. ^ Illuminated entry and courtesy lamps. ^ Driver power window. ^ Accessory delay. ^ 4-wheel drive. ^ Heated backlite/mirror. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > Page 707 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Remote Anti-Theft Personality (RAP) Module Multifunction Electronic Control Modules: Service and Repair Remote Anti-Theft Personality (RAP) Module REMOVAL 1. Disconnect the battery ground cable. CAUTION: ^ Prior to removal of module, it is necessary to upload module configuration information to scan tool. This information needs to be downloaded into the new module once installed. For additional information; refer to Module Communications Network. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Disconnect the Remote Anti-Theft Personality (RAP) module electrical connectors. 3. Remove the nuts and the RAP module. NOTE: On Expedition and later build Navigators, the antenna is internal to the module and must be replaced as an assembly. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Once the new module is installed it is necessary to download the module configuration information from the scan tool into the new module. For additional information; refer to Module Communications Network. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Remote Anti-Theft Personality (RAP) Module > Page 710 Multifunction Electronic Control Modules: Service and Repair Module-Generic Electronic (GEM) REMOVAL 1. Disconnect the battery ground cable. CAUTION: ^ Prior to removal of the module, it is necessary to upload module configuration information to scan tool. This information needs to be downloaded into the new module once installed. For additional information, refer to Module Communications Network. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the steering column cover. For additional information, refer to Dash Board. 3. Remove the (A) bulkhead electrical connectors from the (B) instrument panel fuse junction panel. 4. Remove the (A) instrument panel fuse junction panel bolts and remove the (B) interior fuse junction panel nuts. 5. Disconnect the (A) Generic Electronic Module (GEM) electrical connectors from the (B) GEM. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Remote Anti-Theft Personality (RAP) Module > Page 711 6. Remove the screws and the GEM. INSTALLATION 1. To install, reverse the removal procedure. ^ Check for proper operation. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the scan tool into the new module. For additional information, refer to Module Communications Network. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Remote Anti-Theft Personality (RAP) Module > Page 712 Multifunction Electronic Control Modules: Service and Repair Module-Driver Seat REMOVAL 1. If exposed to these charges, damage may result. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. 2. Remove the driver seat. For additional information, refer to Seats. 3. Disconnect the driver seat module electrical connectors. 4. Remove the screws from the Driver Seat Module (DSM) and release the module retainers from the module bracket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Testing and Inspection Global Positioning System Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Navigation System; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Testing and Inspection Keyless Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Keyless Entry; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Testing and Inspection > Page 719 Keyless Entry Module: Service and Repair RAP/General Module REMOVAL AND INSTALLATION For additional information, refer to Multifunction Electronic Control Modules (General Module). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Locations > Page 723 Navigation Module: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Locations > Page 724 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Service and Repair > Navigation System Display Module Navigation Module: Service and Repair Navigation System Display Module REMOVAL 1. Disconnect the battery. For additional information, refer to Battery. 2. Remove the screw. 3. Carefully pull up on the console finish panel and unsnap it from the center console. 4. Disconnect the harness connectors and parking aid switch (if equipped) and remove the console finish panel. 5. Remove the screws and remove the navigation system display module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Service and Repair > Navigation System Display Module > Page 727 Navigation Module: Service and Repair Navigation System Module REMOVAL 1. Disconnect the battery. Refer to Battery. 2. Remove the lower screws. Unsnap and remove the CD-DJ and Navigation System Module (NSM) cover. 3. Remove the upper screws. 4. Slide the NSM up out of the console, disconnect the three harness connectors and GPS antenna cable and remove the NSM. NOTE: The GPS antenna cable is attached to the NSM with a locking sleeve on the connector Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Service and Repair > Navigation System Display Module > Page 728 5. Remove the two screws on each end of the bracket and remove the NSM. INSTALLATION 1. To install, reverse the removal procedure. ^ Make sure all connectors are correctly locked. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Page 732 Parking Assist Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Collision Avoidance and Parking Assist Systems; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Page 733 Parking Assist Control Module: Service and Repair REMOVAL 1. Remove the RH C-pillar trim panel. 2. Remove the Parking Aid Module (PAM). 1 Disconnect the electrical connectors. 2 Remove the screws. 3 Remove the PAM. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Testing and Inspection Keyless Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Keyless Entry; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Testing and Inspection > Page 738 Keyless Entry Module: Service and Repair RAP/General Module REMOVAL AND INSTALLATION For additional information, refer to Multifunction Electronic Control Modules (General Module). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Testing and Inspection Power Door Lock Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Keyless Entry; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Power Door Lock Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 745 Located in the Lock Relay Block, which is located behind the right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 746 Power Door Lock Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Testing and Inspection Power Mirror Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Mirrors; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Heated Seat Module Power Seat Control Module: Locations Heated Seat Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Heated Seat Module > Page 754 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Heated Seat Module > Page 755 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Heated Seat Module Power Seat Control Module: Diagrams Heated Seat Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Heated Seat Module > Page 758 Power Seat Control Module: Diagrams Driver Memory Seat Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Heated Seat Module > Page 759 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Heated Seat Module > Page 760 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Page 761 Power Seat Control Module: Service Precautions WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Page 762 Power Seat Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Seats; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service and Repair > Seat Module Power Seat Control Module: Service and Repair Seat Module REMOVAL WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. ^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in. side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. ^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. If equipped with side air bags, deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the power seat track. For additional information, refer to Seat Track-Power, with Side Air Bag or Seat Track-Power, without Side Air Bag. 3. Remove the seat module. NOTE: For additional information regarding this component please refer to Multifunction Electronic Control Modules. INSTALLATION 1. To install, reverse the removal procedure. 2. If equipped with side air bags, reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 3. If equipped, prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service and Repair > Seat Module > Page 765 Power Seat Control Module: Service and Repair Heated REMOVAL WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. ^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. ^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. If equipped with side air bags, deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the power seat track. For additional information, refer to Seat Track-Power, with Side Air Bag or Seat Track-Power, without Side Air Bag. 3. Disconnect the electrical connectors. 4. Remove the heated seat module. ^ Release the clip. INSTALLATION 1. To install, reverse the removal procedure. 2. If equipped with side air bags, reactivate the supplemental restraint system For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 3. If equipped, prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Passenger Temperature Controlled Seat Module Seat Heater Control Module: Locations Passenger Temperature Controlled Seat Module Under passenger seat. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Passenger Temperature Controlled Seat Module > Page 770 Seat Heater Control Module: Locations Driver Temperature Controlled Seat Module Under driver seat. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Driver Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Driver > Page 773 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service Precautions > Technician Safety Information Seat Heater Control Module: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service Precautions > Technician Safety Information > Page 776 Seat Heater Control Module: Vehicle Damage Warnings WARNING: ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service Precautions > Page 777 Seat Heater Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Seats; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair Sunroof / Moonroof Module: Service and Repair REMOVAL 1. Close the roof opening panel. 2. Disconnect the battery ground cable. For additional information, refer to Battery. 3. Remove the headliner. 4. Slide the roof opening panel module from the retaining bracket. 5. Disconnect the electrical connectors and remove the roof opening panel module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications Anti-lock brake control module screws 44 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 785 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 786 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 787 Electronic Brake Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 788 Electronic Brake Control Module: Service and Repair Removal and Installation 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Disconnect the anti-lock brake control module electrical connector. 3. Disconnect the pump motor electrical connector from the anti-lock brake control module. 4. Remove the screws and the anti-lock brake control module. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay Blower Motor Relay: Locations Blower Motor Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 794 Located in the Blower/Flasher Relay Block, which is located behind the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 795 Blower Motor Relay: Locations Console Blower Relay Located in the RPO Relay Block #1, which is located in the dash, above the passenger air bag. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay Blower Motor Relay: Testing and Inspection Blower Motor Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 798 Blower Motor Relay: Testing and Inspection Console Blower Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 802 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 803 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 804 Compressor Clutch Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module Control Module HVAC: Locations Electronic Climate Control Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 809 Component Views Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 810 Component Views Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 811 Electronic Automatic Temperature Control Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module Control Module HVAC: Diagrams Electronic Climate Control Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module > Page 814 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module > Page 815 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Page 816 Control Module HVAC: Description and Operation The A/C blower motor speed control is a Pulse Width Modulated (PWM) type which provides variable blower speed control of the blower motor. The A/C blower motor speed control is controlled by switching the control signal voltage of 5 volts OFF and ON 2,000 times per second. By varying the ratio of time on (+5 volts) to time off (0 volts), the EATC module tells the A/C blower motor speed control how fast the blower motor should run. The A/C blower motor speed control has the following features: ^ Has circuitry to protect the blower motor from burning out in the event of a locked rotor condition. ^ Can compensate for changes in battery positive voltage (B+) which prevents the blower speed from slowing down when the engine is idling and will provide up to a maximum of 30 amperes for blower motor operation with battery voltages between 10 and 16 volts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Page 817 Control Module HVAC: Service and Repair REMOVAL 1. Disengage the stops and lower the glove compartment door. 2. Remove the kickpad. 3. Disengage the aspirator hose from the bracket. NOTE: Part shown out of vehicle position. 4. Disengage the blower motor speed control mounting bracket from the instrument panel. 5. Disconnect the connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Page 818 6. Disengage the retaining tabs and remove the blower motor speed control from the mounting bracket. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations System Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations > Page 822 Located in the RPO Relay Block #2, which is located at the front of the left rear wheelwell. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 828 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 829 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 830 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 831 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 832 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 833 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 834 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 835 Audible Warning Device Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 836 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 837 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 838 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 839 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 840 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 841 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Testing and Inspection Fuel Gauge Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 853 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 854 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 855 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Component Information > Service and Repair Spare Tire: Service and Repair Removal 1. Lower the spare tire. 1. Insert the drive end of the jack handle through the opening left of the license plate. 2. Turn the jack handle until slack is present in the cable. 2. Remove the spare tire. 1. Slide the retainer through the center of the spare tire assembly. 2. Remove the spare tire assembly. 3. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 4. Remove the spare tire carrier. 1. Remove the bolts. 2. Turn the spare tire carrier to disengage the spare tire carrier from the tabs and remove the spare tire carrier. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Component Information > Service and Repair > Page 858 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 00-14-2 > Jul > 00 > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 00-14-2 > Jul > 00 > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 868 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 00-14-2 > Jul > 00 > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 869 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 00-14-2 > Jul > 00 > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 870 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Page 871 Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet Air Cleaner (ACL) aside. 2. Remove the (A) Air Cleaner (ACL) element from the (B) open end of the inlet air cleaner. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure the tabs are aligned properly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Testing and Inspection Panel Illumination Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Speedometer Module: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 883 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Speedometer Module: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 889 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction Battery Discharge Protection Relay: Technical Service Bulletins Battery Saver Relay - Malfunction Article No. 00-19-2 09/18/00 ^ LAMP - COURTESY, GLOVE COMPARTMENT, UNDERHOOD, RUNNING BOARD LAMPS INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ POWER WINDOWS - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ RADIO - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ REAR WIPER - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES FORD: 1999-2000 EXPEDITION, F-150, F-250 LD LINCOLN: 1999-2000 NAVIGATOR This article is being republished in its entirety to update the part number. ISSUE A temporary loss of functions controlled by the battery saver relay may occur on some vehicles. These functions may be inoperative for a short period of time after the vehicle has sat unattended for at least 45 minutes. These functions are limited to courtesy and interior/demand lamps, glove compartment, underhood lamps and power windows. Running board lights, moonroof and the rear wiper may be affected on Expedition and Navigator. The radio may also be inoperative during this time on Navigator only. The loss of these features is temporary and can last from a few seconds up to 10-15 minutes. ACTION Replace the Battery Saver Relay (YL3Z-14N089-AA). Refer to the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) for location of this relay. NOTE PERMANENT LOSS OF ANY OF THESE FUNCTIONS SHOULD NOT BE ADDRESSED WITH THIS TSB. FUNCTIONS OTHER THAN THOSE EXPLICITLY MENTIONED ABOVE THAT ARE REPORTED TO BE INOPERATIVE SHOULD NOT BE ADDRESSED WITH THIS TSB. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-8-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION / DESCRIPTION / TIME Table Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction > Page 895 DEALER CODING OASIS CODES: 10200, 204000, 201100, 201200, 202000, 20300, 205000, 207000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 896 Battery Discharge Protection Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 897 The battery saver relay is located in the central junction box (CJB), under the left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 898 Battery Discharge Protection Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations Courtesy Lamp Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 902 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 903 The interior lamp relay is located in the central junction box under the left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 904 Courtesy Lamp Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations Daytime Running Lamp Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 908 Located in the Daytime Running Lamps Relay Block, which is located behind the left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 909 Daytime Running Lamp Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Testing and Inspection Exterior Lighting Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Lighting and Horns; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 916 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 917 Fog/Driving Lamp Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Autolamp Module <--> [Headlamp Control Module] > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Autolamp Module <--> [Headlamp Control Module] > Component Information > Locations > Page 921 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Autolamp Module <--> [Headlamp Control Module] > Component Information > Locations > Page 922 Autolamp Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Lighting and Horns; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Located in the RPO Relay Block #1, which is located in the dash, above the passenger air bag. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 926 Headlamp Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 930 Located in the RPO Relay Block #1, which is located in the dash, above the passenger air bag. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 931 Horn Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions Illuminated Entry Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 936 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 937 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 938 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 939 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 940 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 941 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 942 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 943 Illuminated Entry Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 944 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 945 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 946 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 947 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 948 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 949 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 950 Illuminated Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Lighting and Horns; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations Interior Lighting Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 954 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 955 The interior lamp relay is located in the central junction box under the left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 956 Interior Lighting Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Located in the RPO Relay Block #1, which is located in the dash, above the passenger air bag. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 960 Parking Lamp Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 971 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay Power Distribution Relay: Testing and Inspection Trailer Tow Running Lamp Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 974 Power Distribution Relay: Testing and Inspection Trailer Tow Reversing Lamp Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 975 Power Distribution Relay: Testing and Inspection Trailer Tow Battery Charge Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box Relay Box: Locations Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 980 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 981 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 982 Relay Box: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 983 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 984 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 987 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 988 Relay Box: Diagrams Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 989 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 990 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 991 Relay Box: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 992 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 993 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 994 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box Relay Box: Application and ID Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 997 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 998 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 999 Relay Box: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 1000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 1001 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1012 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1013 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1014 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 1020 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 1021 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1026 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1027 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 1028 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 1034 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 1035 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1036 Powertrain Control Module: Specifications Powertrain Control Module (PCM) Electrical Connector Bolt 5 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1037 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1038 Powertrain Control Module: Diagrams Part 1 Of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1039 Part 2 Of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 1040 Part 3 Of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Engine Emission Control Powertrain Control Module: Description and Operation Engine Emission Control The powertrain control module controls the EGR vacuum regulator solenoid. The EGR vacuum regulator solenoid controls the vacuum to the EGR valve. When the EGR valve opens, exhaust gas flows to the intake manifold. The EGR transducer measures the flow through the EGR valve to exhaust manifold tube and sends a signal to the powertrain control module. A metering orifice in the EGR valve to exhaust manifold tube restricts the flow rate when the EGR valve is open. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Engine Emission Control > Page 1043 Powertrain Control Module: Description and Operation Electronic Engine Control The PCM needs the following inputs to calibrate the engine correctly: ^ engine rpm ^ engine coolant temperature ^ amount of engine detonation ^ crankshaft position ^ air temperature ^ throttle position ^ cylinder head temperature ^ mass air flow Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Page 1044 Powertrain Control Module: Testing and Inspection For information regarding diagnosis of this component refer to Computers and Control Systems Diagnosis. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures Powertrain Control Module: Procedures REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Loosen the bolt and disconnect the electrical connector. 3. Remove the RH front door scuff plate. 4. Remove the RH cowl side trim panel. 5. Remove the clip and the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 1047 Powertrain Control Module: Reset Procedure Flash Electrically Eraseable Programmable Read Only Memory-Flash EEPROM Flash Electrically Eraseable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internal to the PCM. The EEPROM contains the vehicle strategy including calibration information specific to the vehicle. The IC has the capability to be reprogrammed or reflashed. This is described below by the Flash EEPROM Procedure. As part of the calibration there is an area referred to as the Vehicle Identification (VID) Block. The VID block must be programmed when replacing the PCM and is described under Programming the VID Block for a Replacement PCM. The VID block is an existing PCM can also be tailored to accommodate various hardware changes made to the vehicle since production. This is described under Making Changes to the VID Block and also under the FLASH EEPROM Procedure. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VID number, octane adjust, fuel octane. fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, four wheel drive and manual versus non manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to reflash the PCM to reset the VID block. This is accomplished by the Flash EEPROM Procedure. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and in need of programming. There are two 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 will be performed if the old PCM is capable of communicating. This is done by the use of the scan tool to retrieve data from the old PCM before removing from the vehicle. The stored data can now be downloaded to the new PCM after replacing. This same process can also be accomplished during the Flash EEPROM Procedure described below. Manual data entry must be performed if the old module is damaged and not capable of communicating. Remove and replace the old PCM. Contact the "AS BUILT" data center by fax for the data needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used. The following information will need to be faxed in: dealer name, dealer P & A code, dealer phone number, dealer fax number, technician's name, VIN and module being programmed. The necessary VID block data will then be faxed back. Enter the vehicle data string provided by the "AS BUILT" data center. Refer to the Worldwide Diagnostic System users manual for details. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1051 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1052 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 1057 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 1058 The fuel pump relay is located in the battery junction box in the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 1059 Fuel Pump Relay: Description and Operation The fuel pump relay engages the fuel pump when energized by the PCM. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 1060 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1064 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1065 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1070 Air Bag Control Module: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1071 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 1072 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) performs the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash. ^ monitors the air bag Supplemental Restraint System (SRS) for faults. ^ illuminates the air bag indicator if a fault is detected. ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). ^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safing sensor is internal to the RCM and is not repaired separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned OFF and then ON), the air bag indicator will remain lit for six seconds and then go out. If an SRS fault exists, the air bag indicator will then flash a two-digit Lamp Fault Code (LFC). The air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the Data Link Connector (DLC), using a scan tool. If the air bag indicator does not function, and a system fault is detected, the RCM will signal the GEM to activate the audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After the fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that an air bag deployment is required. The backup power supply will deplete its stored energy approximately 1 minute after the battery ground cable is disconnected. Sensor WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. The SRS uses four crash sensors. Two of the sensors are integral to the RCM and not separately serviceable. In addition, there are two side crash sensors mounted beneath their respective seats. The RCM is mounted to the center tunnel beneath the instrument panel. Mounting orientation is critical for correct operation of all crash sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation Air Bag Control Module: Service and Repair Removal and Installation REMOVAL AND INSTALLATION WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. NOTE: Before disconnecting the battery ground cable, move the front seats as far forward as possible. 2. Remove the trinket tray insert. 3. Remove the two screws. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1075 4. Remove the console insert from the console and position it aside. 5. Remove the screws. 6. At the rear of the console, remove the screws (RH and LH side). 7. Lift the center console and position it as far to the rear as the electrical connections will allow. 8. Remove the instrument panel lower finish panel. NOTE: There are two pin-type fasteners on the LH side and one on the RH side. 9. Remove the RCM screw beneath the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1076 10. Disconnect the RCM electrical connectors. 11. Remove the RCM. 1 Remove the screws. 2 Remove the RCM. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG RESTRAINT CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 12. To install, reverse the removal procedure. 13. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1077 Air Bag Control Module: Service and Repair General Procedures "J" Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure. Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor Weld nuts must he installed in Weld Nut Repair - Missing Weld Nut, Restraints Control Module ( RCM) and Side Crash Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-5301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Missing Weld Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts as outlined in Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-5190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-5190). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 1078 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Stripped Weld Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190) 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation Seat Belt Warning Relay: Technical Service Bulletins Seat Belts - Warning System Operation Article No. 01-2-5 2/05/01 ^ TRIM - SEAT BELT WARNING SYSTEM - "BELT ^ MINDER" FUNCTION - OPERATION AND SERVICE ^ TIPS ^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND ^ SERVICE TIPS FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION, F-150, RANGER, WINDSTAR 2001 EXPLORER LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER ISSUE The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the instrument cluster. ACTION Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following Service Procedure. SERVICE PROCEDURE To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure. 1. Establish a session for the vehicle. 2. Select the "Toolbox" icon. 3. Select "Module Programming" and press the "Tick" mark. 4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark. 5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark. 6. WDS will display "Configuration Complete", then press the "Tick" mark. NOTE: IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE SAFETY BELT IS BUCKLED. NOTE: WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND FOR 4-8 SECONDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation > Page 1083 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 104000, 204000, 206000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Charging System Control Module > Component Information > Description and Operation Charging System Control Module: Description and Operation Generator Load The Generator Load Input (GLI) circuit is used by the PCM to determine generator load on the engine. As generator load increases the PCM will adjust idle speed accordingly. This strategy helps reduce idle surges due to switching high current loads. The GLI signal is sent to the PCM from the voltage regulator/generator. The signal is a variable frequency duty cycle. Normal operating frequency is 40 - 250 Hz. Normal signal DC voltage (referenced to ground) is between 1.5 V (low generator load) and 10.5 V (high generator load). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Diagrams > Air Suspension/Electronic Variable Orifice Steering Module Steering Control Module: Diagrams Air Suspension/Electronic Variable Orifice Steering Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Diagrams > Air Suspension/Electronic Variable Orifice Steering Module > Page 1098 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 1111 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 1112 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 1118 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 1119 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 1120 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Service and Repair > Rear Only System Suspension Control Module: Service and Repair Rear Only System Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Remove the instrument panel cluster panel. 3. Remove the air suspension control module screws. 4. Remove the air suspension control module and bracket assembly. 1. Disconnect the electrical connectors. 2. Remove the air suspension control module and bracket assembly. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Note: The air suspension control module is calibrated with information from the ride height sensor. A new or exchanged air suspension control module requires that the ride height adjustment calibration process be performed; refer to Front Ride Height Resetting - Clear B2140 DTC. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Service and Repair > Rear Only System > Page 1123 Suspension Control Module: Service and Repair 4-Wheel System Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Remove the instrument panel cluster panel. 3. Remove the air suspension control module screws. 4. Remove the air suspension control module and bracket assembly. 1. Disconnect the electrical connectors. 2. Remove the air suspension control module and bracket assembly. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Note: The air suspension control module is calibrated with information from the ride height sensor. A new or exchanged air suspension control module requires that the ride height adjustment calibration process be performed; refer to Front Ride Height Resetting - Clear B2140 DTC. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 1134 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 1135 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 1141 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 1142 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1145 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1146 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1147 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1148 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1149 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1150 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1151 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1152 Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1153 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1154 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1155 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1156 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1157 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 1158 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque on Demand Relay Four Wheel Drive Selector Relay: Locations Torque on Demand Relay The Torque on Demand relay is located behind the center of the Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque on Demand Relay > Page 1163 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay The Torque on Demand relay is located behind the center of the Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque on Demand Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque on Demand Relay > Page 1166 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions Heated Glass Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1172 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1173 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1174 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1175 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1176 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1177 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1178 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1179 Heated Glass Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1180 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1181 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1182 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1183 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1184 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1185 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Page 1186 Heated Glass Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Windows; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1190 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 1191 Heated Glass Element Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Window Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1196 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1197 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1198 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1199 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1200 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1201 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1202 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1203 Power Window Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1204 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1205 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1206 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1207 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1208 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1209 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 1210 Power Window Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Windows; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Accessory Delay Relay Power Window Relay: Locations Accessory Delay Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 1215 The accessory delay relay is located in the central junction box, under the dash panel, LH side. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 1216 Power Window Relay: Locations One Touch Down Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 1217 The one touch down relay is located in the central junction box, under the dash panel, LH side. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 1218 Power Window Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1224 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1225 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1226 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1227 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1228 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1229 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1230 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1231 Windshield Washer Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1232 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1233 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1234 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1235 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1236 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1237 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Rear Washer Pump Relay Windshield Washer Relay: Locations Rear Washer Pump Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Rear Washer Pump Relay > Page 1242 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Rear Washer Pump Relay > Page 1243 Windshield Washer Relay: Locations Washer Pump Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Rear Washer Pump Relay > Page 1244 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 1245 Windshield Washer Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions Wiper Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1250 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1251 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1252 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1253 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1254 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1255 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1256 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1257 Wiper Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1258 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1259 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1260 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1261 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1262 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1263 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 1264 Wiper Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Wiper and Washer Systems; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay Wiper Relay: Locations Wiper High/Low Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 1269 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 1270 Wiper Relay: Locations Wiper Run/Park Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 1271 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 1272 Wiper Relay: Locations Rear Wiper Up Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 1273 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 1274 Wiper Relay: Locations Rear Wiper Down Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 1275 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Wiper High/Low Relay Wiper Relay: Testing and Inspection Wiper High/Low Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Wiper High/Low Relay > Page 1278 Wiper Relay: Testing and Inspection Wiper Run/Park Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Wiper High/Low Relay > Page 1279 Wiper Relay: Testing and Inspection Rear Wiper Up Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Wiper High/Low Relay > Page 1280 Wiper Relay: Testing and Inspection Rear Wiper Down Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Specifications Parking Assist Distance Sensor: Specifications Azimuth System Check Object Position 1 (P1) And Position 5 (P5), Distance From Sensor 30.48 cm Azimuth System Check Object Position 2 (P2) And Position 4 (P4) , Distance From Sensor 91.44 cm Azimuth System Check Object Position 3 (P3), Distance From Sensor 152.4 cm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Left Center Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Left Center Sensor > Page 1288 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Left Center Sensor > Page 1289 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Left Center Sensor > Page 1290 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Page 1291 Parking Assist Distance Sensor: Service and Repair REMOVAL 1. Remove the parking aid sensor. 1 Disconnect the electrical connector. 2 Release the tabs. 3 Remove the parking aid sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams > Page 1295 Parking Assist Switch: Service and Repair REMOVAL 1. Remove the front floor console finish panel. For additional information, refer to Console. 2. Remove the parking aid switch. ^ Release the tabs. ^ Remove the parking aid switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Right Front Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Right Front > Page 1301 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front Power Door Lock Switch: Testing and Inspection Left Front Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 1304 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 1305 Power Door Lock Switch: Testing and Inspection Right Front Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 1306 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 1310 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Exterior Rear View Mirror Switch Power Mirror Switch: Testing and Inspection Exterior Rear View Mirror Switch Component Testing Procedure (Part 1 Of 2) Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Exterior Rear View Mirror Switch > Page 1313 Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Exterior Rear View Mirror Switch > Page 1314 Power Mirror Switch: Testing and Inspection Power Folding Mirror Switch Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Exterior Rear View Mirror Switch > Page 1315 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Heated Seat Switch Power Seat Switch: Diagrams Heated Seat Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Heated Seat Switch > Page 1320 Power Seat Switch: Diagrams Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Heated Seat Switch > Page 1321 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Heated Seat Switch > Page 1322 Power Seat Switch: Diagrams Power Lumbar Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information Power Seat Switch: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information > Page 1325 Power Seat Switch: Vehicle Damage Warnings WARNING: ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Power Seat Switch: Testing and Inspection Driver Without Memory Component Testing Procedure (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 1328 Component Testing Procedure (Part 2 Of 2) Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 1329 Schematic With Memory Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 1330 Component Testing Procedure (Part 1 Of 2) Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 1331 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 1332 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 1333 Power Seat Switch: Testing and Inspection Passenger Without Lumbar Component Testing Procedure (Part 1 Of 2) Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 1334 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 1335 Schematic With Lumbar Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 1336 Component Testing Procedure (Part 1 Of 2) Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 1337 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 1338 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch Power Seat Switch: Service and Repair Seat Control Switch Without Side Air Bags REMOVAL NOTE: Driver side shown, passenger side similar. 1. Disconnect the battery ground cable. 2. Remove the front seat back adjust handle. 1 Remove the screw. 2 Remove the front seat back adjust handle. 3. Pull to remove the front seat lumbar support handle. 4. Remove the front seat track shield screws. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 1341 5. Remove the pin-type retainer on the back of the front seat track shield. 6. Remove the screws on the bottom of the front seat track shield. 7. Disconnect the seat regulator control switch from the front of the front seat track shield. 1 Remove the screws. 2 Disconnect the seat regulator control switch. NOTE: If equipped with heated seats, disconnect the switch. 8. Disconnect the seat regulator control switch electrical connector and remove the seat regulator control switch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 1342 1. To install, reverse the removal procedure. NOTE: ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. ^ If equipped with heated seats, connect the switch. With Side Air Bags WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 1343 ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems of the appropriate car/truck service manual. ^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. ^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. ^ Navigator is shown, Expedition is similar. REMOVAL 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the seat from the vehicle. For additional information, refer to Front Seat-Captain's Chair with Side Air Bag. 3. Remove the screw and the seat latch handle. 4. Remove the screw. 5. From the front underside of the seat cushion frame, remove and disconnect the seat control and climate control switch (if equipped) electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 1344 6. Remove the screws. 7. Remove the pin-type retainer. 8. Remove the side shield. 1 Pull the side shield out far enough and disconnect the power lumbar switch. 2 Pull the wire harnesses through the seat cushion frame and remove the side shield. 9. Remove the seat control switch from the side shield. 1 Remove the screws. 2 Remove the seat control switch. INSTALLATION 1. To install, reverse the removal procedure. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 1345 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 3. If equipped, prove out the air bag system. For additional information, refer to Air Bag systems. 4. Check the restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 1346 Power Seat Switch: Service and Repair Lumbar Control Switch WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems of the appropriate car/truck service manual. ^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. ^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. REMOVAL 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the seat from the vehicle. For additional information, refer to Front Seat-Captain's Chair with Side Air Bag. 3. Remove the screw and the seat latch handle. 4. Remove the screw. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 1347 5. From the front underside of the seat cushion frame, remove and disconnect the seat control and climate control switch (if equipped) electrical connectors. 6. Remove the screws. 7. Remove the pin-type retainer. 8. Remove the side shield. 1 Pull the side shield out far enough to access the power lumbar switch and disconnect the switch. 2 Pull the wire harnesses through the seat cushion frame and remove the side shield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 1348 9. Remove the lumbar control switch from the side shield. ^ Release the tabs and remove the lumbar control switch. INSTALLATION 1. To install, reverse the removal procedure. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 3. If equipped, prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Driver Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Driver > Page 1353 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Specifications Brake Fluid Level Sensor/Switch: Specifications Brake pressure switch ......................................................................................................................... ........................................... 14-20 Nm (11-14 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Specifications > Page 1364 Brake Fluid Level Sensor/Switch: Description and Operation The brake fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid from either the primary (front) or secondary (rear) system will cause this system to activate. If the brake fluid level warning switch is inoperative, a new brake master cylinder reservoir must be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Differential Speed Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications Parking brake remote release to instrument panel bolts: 2.1-2.9 Nm (18.7-25.8 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Specifications > Page 1371 Parking Brake Release Switch: Service and Repair Removal and Installation 1. Disconnect the battery. 2. Note: Move the shift lever to the 1 position to case removal. Carefully pry to release four clips and remove the steering column opening cover. 3. Pull to release the three clips and remove the instrument panel fuse door. 4. Position the hood latch release handle aside. 1. Remove the screws. 2. Position the hood latch release handle aside. 5. Position the parking brake release handle aside. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Specifications > Page 1372 1. Remove the screws. 2. Position the parking brake release handle aside. 6. Remove the instrument panel steering column cover. 1. Remove the bolts. 2. Remove the instrument panel steering column cover. 7. Remove the nuts and the instrument panel opening cover support. 8. Loosen the rear nuts. Remove the front nuts and lower the steering column. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Specifications > Page 1373 9. Disconnect the electrical connector. 10. Remove the bolts and the transmission shift selector position insert with attached switch. 11. To install, reverse the removal procedure. ^ Make sure the transmission shift selector position insert is correctly installed onto the brake shift interlock solenoid and the shift lever. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Specifications Parking Brake Warning Switch: Specifications Parking brake signal switch screw ..................................................................................................................................................... 2-3 Nm (18-27 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front anti-lock brake sensor bolt 63 - 80 in.lb Rear anti-lock brake sensor bolt 20 ft.lb Anti-lock brake sensor screws 89 - 123 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Right Front Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Right Front > Page 1382 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front Wheel Speed Sensor: Service and Repair Sensor, Front Removal 1. Disconnect the front brake anti-lock sensor electrical connector. 2. Remove the front disc brake rotor shield. 3. Remove the (A) front brake anti-lock sensor bolts and the (B) front brake anti-lock sensor. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 1385 Wheel Speed Sensor: Service and Repair Sensor, Rear Removal 1. Raise and support vehicle. 2. Note: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1. Disconnect the rear anti-lock brake sensor electrical connector. 2. Remove the bolt. 3. Remove the rear anti-lock brake sensor. Installation 1. Note: Thoroughly clean the mounting surface. Note: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with SAE-75W-140 High Performance Rear Axle Lubricant FITZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor 20 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder head temperature sensor (CHT) 18 - 20 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 1394 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor Engine Temperature Sensor: Description and Operation CHT Sensor The CHT sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends a signal to the PCM indicating cylinder head temperature. ^ If the temperature exceeds 126°C (258°F) 5.4L, 130°C (265°F) 4.6L, the PCM disables four fuel injectors at a time. The PCM will alternate which four fuel injectors are disabled every 32 engine cycles. The four cylinders the are not being fuel injected act as air pumps to aid in cooling the engine. ^ If the temperature exceeds 154°C (310°F) 5.4L, 166°C (330°F) 4.6L, the PCM disables all of the fuel injectors until the engine temperature drops below 154°C (310°F) 5.4L, 153°C (308°F) 4.6L. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor > Page 1397 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor communicates an overheating condition to the PCM. The PCM would then initiate a cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using a CHT sensor and cooling strategy would prevent damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > Page 1398 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting or jacking an air suspension vehicle.This can be accomplished by turning off the air suspension switch located below the glove box in the lower right of the passenger foot well. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during the operations. Failure to follow the instructions may result in personal injury. Raise the vehicle on a hoist. 2. Remove the right front fender splash shield. 3. Remove the dual converter Y-pipe. 4. Remove the components in the order indicated in the following illustration and table. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Water temperature indicator sender unit 15 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 1402 Temperature Sensor (Gauge): Description and Operation Engine Coolant Temperature Gauge Engine coolant temperature information is received by the instrument cluster from the PCM over the SCP network. Temperatures over 121°C (275°F) will display hot (H). If the engine coolant temperature data is missing or invalid for five seconds, the instrument cluster will move the engine coolant temperature gauge below the cold (C) position. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1412 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1413 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1414 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1415 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1416 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1417 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1418 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1419 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1420 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1421 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1422 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1423 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1424 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1425 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1426 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1427 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1428 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1429 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1430 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1431 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1432 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1433 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1434 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1435 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1436 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1437 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 1442 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA05V017000 > Jan > 05 > Recall 05V017000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): Recalls Recall 05V017000: Cruise Control Deactivation Switch MAKE/MODELS: MODEL/BUILD YEARS: Ford/Expedition 2000 Ford/F150 2000 Ford/Supercrew 2001 Lincoln/Navigator 2000 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V017000 RECALL DATE: Jan 27, 2005 COMPONENT: Vehicle Speed Control: Cruise Control POTENTIAL NUMBER OF UNITS AFFECTED: 738490 SUMMARY: On certain sport utility vehicles and pickup trucks, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: This condition could lead to a fire. Fires have occurred while the vehicles were parked with the ignition "OFF." REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (early April 2005), Owners will be instructed to return to the dealers for installation of a new switch. Owners should contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1456 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1457 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1458 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1459 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1460 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1461 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1462 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1463 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1464 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1465 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1466 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1467 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1468 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1469 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1470 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1471 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1472 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1473 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1474 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1475 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1476 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1477 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1478 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1479 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1480 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1481 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 1486 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA05V017000 > Jan > 05 > Recall 05V017000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): All Technical Service Bulletins Recall 05V017000: Cruise Control Deactivation Switch MAKE/MODELS: MODEL/BUILD YEARS: Ford/Expedition 2000 Ford/F150 2000 Ford/Supercrew 2001 Lincoln/Navigator 2000 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V017000 RECALL DATE: Jan 27, 2005 COMPONENT: Vehicle Speed Control: Cruise Control POTENTIAL NUMBER OF UNITS AFFECTED: 738490 SUMMARY: On certain sport utility vehicles and pickup trucks, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: This condition could lead to a fire. Fires have occurred while the vehicles were parked with the ignition "OFF." REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (early April 2005), Owners will be instructed to return to the dealers for installation of a new switch. Owners should contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 1495 Brake Switch (Cruise Control): Specifications Deactivator Switch 18 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information Brake Switch (Cruise Control): Technician Safety Information WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information > Page 1498 Brake Switch (Cruise Control): Vehicle Damage Warnings 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. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 1499 Brake Switch (Cruise Control): Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 1500 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the deactivator switch electrical connector. 3. Remove the deactivator switch. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. INSTALLATION 1. To install, reverse the removal procedure. NOTE: After the deactivator switch is installed, it is necessary to bleed the brake system; refer to Brakes. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 1517 Cruise Control Switch: Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 1518 Cruise Control Switch: Service and Repair REMOVAL 1. Remove the driver side air bag module. Refer to Air Bag Systems. 2. Remove the speed control actuator switch. 1 Release the four (A) speed control actuator switch clips and remove the (B) speed control actuator switch. 2 Disconnect the speed control actuator switch electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Sender: Customer Interest Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 1528 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Sender: All Technical Service Bulletins Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 1534 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Specifications Oil Pressure Sensor: Specifications Oil Pressure sensor 107 - 142 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Service and Repair Air Conditioning Switch: Service and Repair REMOVAL 1. Remove the control assembly. For additional information, refer to Control Assembly-Manual A/C. 2. Remove the function selector. 1 Depress the snap tabs. 2 Remove the function selector. NOTE: The knob will drop off as the function selector is removed. 3. Remove the temperature blend control switch. 1 Remove the screw. 2 Rotate and pull the temperature blend control switch. NOTE: The knob will drop off as the temperature blend control switch is removed. 4. Remove the blower motor switch. 1 Depress the snap tabs. 2 Remove the blower motor switch. NOTE: The knob will drop off as the blower motor switch is removed. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Ambient Temperature Sensor / Switch HVAC: Specifications Ambient Air Sensor Bracket Bolt 9 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 1545 Ambient Temperature Sensor / Switch HVAC: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 1546 Electronic Automatic Temperature Control Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 1547 Ambient Temperature Sensor / Switch HVAC: Description and Operation The A/C ambient air temperature sensor and bracket: ^ is located in front of the A/C condenser core near the center of the vehicle. ^ contains a thermistor which measures the temperature of outside air as a resistance and sends that reading to the EATC module. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 1548 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Remove the pin-type retainers and remove the radiator sight shield. 2. Disconnect the connector. 3. Remove the bolt and remove the ambient air temperature sensor panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Front Blower Motor Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Front Blower Motor Switch > Page 1553 Blower Motor Switch: Diagrams Rear Blower Motor Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations Cabin Temperature Sensor / Switch: Locations Component Views Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 1557 Component Views Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 1558 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 1559 Cabin Temperature Sensor / Switch: Description and Operation The in-car temperature sensor operates in the following manner: ^ A thermistor in the in-car temperature sensor measures air temperature inside the passenger compartment. ^ An automatic temperature control sensor hose and elbow is connected between the plenum assembly and the in-car temperature sensor. ^ The automatic temperature control sensor hose and elbow uses air from the plenum assembly air stream to create a suction at the in-car temperature sensor. ^ The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 1560 Cabin Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the center instrument panel finish panel. 1 Carefully pry to release the four clips. 2. If equipped, disconnect the 4WD control switch connector. 3. Remove the steering column cover panel. 4. Remove the headlamp switch. For additional information, refer to Lighting and Horns. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 1561 5. Remove the LH instrument panel finish panel. 1 Remove the screws. 2 Remove the LH instrument panel finish panel. 6. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. 7. Remove the screw. 8. Disconnect the electrical connector and remove the sensor from the hose. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications Refrigerant Pressure Sensor / Switch: Mechanical Specifications Pressure Cut Off Switch 6.8 - 13.6 Nm Junction block bracket screw 12 Nm Starter relay cable nut 8 Nm Starter relay cable ends 8 Nm A/C Cycling Switch 324 kPa Close Maximum A/C Cycling Switch 152 kPa Open Minimum Pressure Cut Off Switch 6.8 - 13.6 Nm Junction block bracket screw 12 Nm Starter relay cable nut 8 Nm Starter relay cable ends 8 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 1566 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications A/C Cycling Switch 324 kPa Close Maximum A/C Cycling Switch 152 kPa Open Minimum A/C Compressor Pressure Relief Valve 3103 kPa Opens At Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch Refrigerant Pressure Sensor / Switch: Locations Compressor Cut-Off/Cycling Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 1569 Manual A/C Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 1570 Electronic Automatic Temperature Control Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 1571 Refrigerant System Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 1572 Component Views Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 1573 Component Views Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 1574 Refrigerant Pressure Sensor / Switch: Locations A/C Pressure Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 1575 Manual A/C Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 1576 Electronic Automatic Temperature Control Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 1577 Refrigerant System Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 1578 Component Views Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 1579 Component Views Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Sensor Air Conditioning Pressure Sensor Typical Air Conditioning Pressure Sensor A/C Pressure Sensor Output Voltage VS Pressure Chart The Air Conditioning Pressure (A/C pressure) sensor is located in the high pressure (discharge) side of the air conditioning A/C system. The A/C pressure sensor provides a voltage signal to the Powertrain Control Module (PCM) that is proportional to the A/C pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor > Page 1582 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator. ^ A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. ^ This allows the suction pressure inside the suction accumulator to control the operation of the A/C cycling switch. ^ The electrical switch contacts open when the suction pressure drops to 152 - 193 kPa (22 - 28 psi). ^ The contacts close when the suction pressure rises to 276 - 324 kPa (40 - 47 psi). ^ When the A/C cycling switch contacts close, the A/C clutch field coil is energized. ^ When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. ^ The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. ^ This prevents icing of the A/C evaporator core and blockage of airflow. ^ It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Wide Open Throttle A/C Cut-Off Wide Open Throttle A/C Cut-Off Mustang The Wide Open Throttle Air Conditioning Cut-off (WAC) output is used by the PCM to disengage the A/C clutch when A/C compressor operation is not desirable. Under normal conditions, with the A/C off, the PCM will ground the WAC output, which opens the normally closed WOT A/C cut-off relay inside the constant control relay module. When the A/C demand switch is turned on, and the A/C cycling switch and A/C high pressure switch high pressure contacts are closed, voltage is supplied to the WOT A/C cut-off relay contacts and to the ACCS circuit. The voltage on the ACCS circuit indicates to the PCM that A/C is requested. The PCM will then verify that A/C clutch operation is desirable (for example, engine not cranking, overheated or not at WOT). If A/C clutch operation is desirable, the PCM will adjust idle speed as necessary and "unground" the WAC output. This closes the normally closed WOT A/C cut-off relay and allows voltage to be supplied to the A/C clutch. All Others For these applications, the wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), ACCS). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the WAC output, closing the relay contacts and sending voltage to the A/C clutch. Air Conditioning Cycling Switch PCM Inputs Air Conditioning Cycling Switch The Air Conditioning (A/C) cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C cycling switch opens, the PCM will turn off the A/C clutch. For information on the specific function of the A/C cycling switch, refer to Climate Control system. The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are closed, voltage is supplied to the ACCS circuit at the PCM. Refer to the applicable Wiring Diagram 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. For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. NOTE: The Town Car, Continental, LS6/LS8 and Windstar 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 BUS + and BUS - (SCP) communication. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor > Page 1583 Air Conditioning High Pressure Switch Typical Air Conditioning Pressure Sensor Air Conditioning 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 two-speed 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 will result 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 will then turn on the high speed fan to help reduce the pressure. The A/C pressure cutoff switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. ^ The A/C pressure cutoff switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. ^ A valve depressor, located inside the threaded end of the A/C pressure cutoff switch, presses on the Schrader valve stem. ^ This allows the A/C pressure cutoff switch to monitor the compressor discharge pressure. ^ When the compressor discharge pressure rises to approximately 2,896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. ^ When the pressure drops to approximately 1724 kPa (250 psi) the contacts close to allow operation of the A/C compressor. ^ It is not necessary to discharge the refrigerant system to remove the A/C pressure cutoff switch. For additional information, refer to the Wiring Diagrams. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Compressor Cut-Off/Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair Compressor Cut-Off/Cycling Switch REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the junction block splash shield. 3. Disconnect the cable ends. 4. Remove the junction block bracket. 1 Disengage the connector. 2 Remove the screws. 3 Remove the junction block bracket. 5. Disconnect the A/C cycling pressure switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Compressor Cut-Off/Cycling Switch > Page 1586 6. Remove the A/C cycling switch from the top of the suction accumulator. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seal with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C), or equivalent, meeting Ford specification WSH-M1C231-B. 2. Carry out the refrigerant system Leak Detection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Compressor Cut-Off/Cycling Switch > Page 1587 Refrigerant Pressure Sensor / Switch: Service and Repair Pressure Cutoff Switch REMOVAL 1. Disconnect the electrical connector. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. To install, reverse the removal procedure. 1 Lubricate the O-ring seal with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C), or equivalent, meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 1591 Solar Sensor: Description and Operation The A/C sunload sensor: ^ is located on the top side of the instrument panel. ^ contains a photovoltaic diode that is sensitive to light. ^ has some unspecified resistance across the terminals depending upon the amount of light reaching the photovoltaic diode; therefore the only test that can be performed is for an internal short circuit. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 1592 Solar Sensor: Service and Repair REMOVAL 1. Remove the instrument panel upper finish panel. 2. Disconnect the connector. 3. Remove the A/C sunload sensor from the instrument panel upper finish panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Directional Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Directional Sensor > Component Information > Locations > Page 1597 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair Door Switch: Service and Repair For additional information, refer to Body and Frame; Doors, Hood and Trunk. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation Fuel Gauge Sender: Description and Operation The "Gasoline System" information is not available at this time. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Specifications Parking Brake Warning Switch: Specifications Parking brake signal switch screw ..................................................................................................................................................... 2-3 Nm (18-27 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Diagrams > 4R70W Transmission Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Diagrams > 4R70W Transmission > Page 1613 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 1617 Brake Light Switch: Description and Operation Brake Pedal Position Switch Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 1618 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the Brake Pedal Position (BPP) switch connector. 2. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the spacer. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1627 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1628 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1629 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1630 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1631 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1632 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1633 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1634 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1635 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1636 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1637 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1638 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1644 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1645 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1646 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1647 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1648 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1649 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1650 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1651 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1652 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1653 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1654 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 1655 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Page 1656 Multifunction Switch: Testing and Inspection For further information regarding this component please refer to Turn Signal Switch; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Page 1657 Multifunction Switch: Service and Repair For further information regarding this component please refer to Turn Signal Switch; Service and Repair. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair Door Switch: Service and Repair For additional information, refer to Body and Frame; Doors, Hood and Trunk. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 1664 Hazard Warning Switch: Description and Operation The steering column switches consist of the: ^ multifunction switch, which controls the: ^ turn signal. ^ hazard flasher. ^ windshield wiper/washer. ^ rear wiper/washer. ^ headlamp dimmer/flash-to-pass. ^ ignition switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Hazard Warning Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1667 Hazard Warning Switch: Diagnostic Trouble Code Descriptions Generic Electronic Module (GEM) DTC Index B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1668 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1669 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1670 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1671 P1836-P1891 Part 5 of 5 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1672 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1673 Part 3 of 3 GEM Active Command Index Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1674 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1675 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1676 Hazard Warning Switch: Pinpoint Tests Test A: No Communication With the Module-GEM Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1677 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1678 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1679 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1680 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1681 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1682 Hazard Warning Switch: Testing and Inspection Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Generic Electronic Module (GEM) DTC Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1683 B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1684 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1685 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1686 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1687 P1836-P1891 Part 5 of 5 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1688 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1689 Part 3 of 3 GEM Active Command Index Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1690 Part 2 of 2 Test A: No Communication With the Module-GEM Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1691 Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1692 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1693 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1694 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1695 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1696 Part 2 of 2 Component Tests and General Diagnostics Multifunction Switch Tests Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1697 Component Testing Procedure Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1698 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1699 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1700 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 1701 Hazard Warning Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Note: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 1702 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the multi function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the multi function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 1706 Headlamp Dimmer Switch: Description and Operation The steering column switches consist of the: ^ multifunction switch, which controls the: ^ turn signal. ^ hazard flasher. ^ windshield wiper/washer. ^ rear wiper/washer. ^ headlamp dimmer/flash-to-pass. ^ ignition switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Headlamp Dimmer Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1709 Headlamp Dimmer Switch: Diagnostic Trouble Code Descriptions Generic Electronic Module (GEM) DTC Index B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1710 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1711 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1712 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1713 P1836-P1891 Part 5 of 5 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1714 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1715 Part 3 of 3 GEM Active Command Index Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1716 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1717 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1718 Headlamp Dimmer Switch: Pinpoint Tests Test A: No Communication With the Module-GEM Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1719 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1720 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1721 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1722 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1723 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1724 Headlamp Dimmer Switch: Testing and Inspection Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Generic Electronic Module (GEM) DTC Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1725 B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1726 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1727 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1728 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1729 P1836-P1891 Part 5 of 5 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1730 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1731 Part 3 of 3 GEM Active Command Index Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1732 Part 2 of 2 Test A: No Communication With the Module-GEM Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1733 Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1734 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1735 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1736 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1737 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1738 Part 2 of 2 Component Tests and General Diagnostics Multifunction Switch Tests Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1739 Component Testing Procedure Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1740 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1741 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1742 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 1743 Headlamp Dimmer Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Note: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 1744 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the multi function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the multi function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams Main Light Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1748 Main Light Switch: Service Precautions CAUTION: Cover the end of the tool with tape to prevent damage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1749 Main Light Switch: Testing and Inspection Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1750 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1751 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 1752 Main Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable, For additional information, refer to Battery. 2. Insert a thin tool to remove the headlamp switch. CAUTION: Cover the end of the tool with tape to prevent damage. 3. Disconnect the electrical connectors. INSTALLATION 1. To install reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair Steering Wheel Pad Horn Switch REMOVAL AND INSTALLATION NOTE: The steering wheel pad horn switch is part of the driver side air bag module. For additional information, refer to Air Bag Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Service and Repair Interior Light Switch: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the electrical connector. 2 Rotate the interior lamp switch counterclockwise to remove. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1762 Turn Signal Switch: Description and Operation The steering column switches consist of the: ^ multifunction switch, which controls the: ^ turn signal. ^ hazard flasher. ^ windshield wiper/washer. ^ rear wiper/washer. ^ headlamp dimmer/flash-to-pass. ^ ignition switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Turn Signal Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1765 Turn Signal Switch: Diagnostic Trouble Code Descriptions Generic Electronic Module (GEM) DTC Index B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1766 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1767 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1768 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1769 P1836-P1891 Part 5 of 5 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1770 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1771 Part 3 of 3 GEM Active Command Index Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1772 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1773 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1774 Turn Signal Switch: Pinpoint Tests Test A: No Communication With the Module-GEM Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1775 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1776 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1777 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1778 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1779 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1780 Turn Signal Switch: Testing and Inspection Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Generic Electronic Module (GEM) DTC Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1781 B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1782 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1783 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1784 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1785 P1836-P1891 Part 5 of 5 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1786 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1787 Part 3 of 3 GEM Active Command Index Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1788 Part 2 of 2 Test A: No Communication With the Module-GEM Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1789 Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1790 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1791 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1792 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1793 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1794 Part 2 of 2 Component Tests and General Diagnostics Multifunction Switch Tests Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1795 Component Testing Procedure Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1796 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1797 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1798 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 1799 Turn Signal Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Note: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 1800 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the multi function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the multi function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow (MAF) Sensor Plate Nuts 10 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 1806 Mass Air Flow Sensor: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 1807 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 1808 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 1809 Mass Air Flow Sensor: Service Precautions CAUTION: ^ Do not tamper with the sensing elements located in the Mass Air Flow (MAF) sensor. Tampering may result in unit failure. ^ The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > General Mass Air Flow Sensor: Description and Operation General The MAF sensor: ^ sends the PCM a signal indicating mass airflow rate of air entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > General > Page 1812 Mass Air Flow Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (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 ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass 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. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > Page 1813 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Open the air cleaner. ^ Disconnect the MAF sensor extension harness connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the air cleaner from the outlet side of the air cleaner. CAUTION: Do not tamper with the sensing elements located in the Mass Air Flow (MAF) sensor. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and serviced as a unit. 2. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. 3. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > Page 1814 4. Remove the MAF sensor plate and the MAF sensor from the outlet side of the air cleaner. 5. Disconnect the MAF sensor electrical connector from the extension harness. 6. Separate the MAF sensor plate from the MAF sensor. ^ Remove the nuts from the MAF sensor plate. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to correctly align the inlet side and the outlet side of the air cleaner. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft position sensor bolt 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 1818 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > General Camshaft Position Sensor: Description and Operation General The CMP sensor: ^ sends the PCM a signal indicating camshaft position used for fuel synchronization. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > General > Page 1821 Camshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 1822 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor 20 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft position sensor bolt 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1832 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (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 Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 1835 Crankshaft Position Sensor: Description and Operation Engine Ignition The CKP sensor: ^ is a variable reluctance sensor. ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. ^ provides base timing and crankshaft speed (rpm) to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 1836 Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 1837 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the A/C compressor. For additional information, refer to Heating and Air Conditioning. 2. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder head temperature sensor (CHT) 18 - 20 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 1841 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor Engine Temperature Sensor: Description and Operation CHT Sensor The CHT sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends a signal to the PCM indicating cylinder head temperature. ^ If the temperature exceeds 126°C (258°F) 5.4L, 130°C (265°F) 4.6L, the PCM disables four fuel injectors at a time. The PCM will alternate which four fuel injectors are disabled every 32 engine cycles. The four cylinders the are not being fuel injected act as air pumps to aid in cooling the engine. ^ If the temperature exceeds 154°C (310°F) 5.4L, 166°C (330°F) 4.6L, the PCM disables all of the fuel injectors until the engine temperature drops below 154°C (310°F) 5.4L, 153°C (308°F) 4.6L. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor > Page 1844 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor communicates an overheating condition to the PCM. The PCM would then initiate a cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using a CHT sensor and cooling strategy would prevent damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Page 1845 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting or jacking an air suspension vehicle.This can be accomplished by turning off the air suspension switch located below the glove box in the lower right of the passenger foot well. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during the operations. Failure to follow the instructions may result in personal injury. Raise the vehicle on a hoist. 2. Remove the right front fender splash shield. 3. Remove the dual converter Y-pipe. 4. Remove the components in the order indicated in the following illustration and table. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Pressure Sensor > Component Information > Description and Operation Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure Sensor Fuel Rail Pressure (FRP) Sensor Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. The Fuel Rail Pressure (FRP) sensor senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 1852 Fuel Tank Pressure Sensor: Service Precautions CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down while rotating the sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Fuel Tank Pressure Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor or Inline Fuel Tank Pressure (FTP) sensor is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 1855 Fuel Tank Pressure Sensor: Description and Operation The Fuel Tank Pressure (FTP) sensor: ^ monitors the pressure levels in the fuel tank. ^ communicates the pressure reading to the PCM during the OBD II leak test. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 1856 Fuel Tank Pressure Sensor: Description and Operation Principles of Operation The fuel tank pressure sensor is used to measure the fuel tank pressure during the Evaporative Emissions Monitor Test. It is also used to control excessive fuel tank pressures by forcing the system to purge. The FTP sensor is tank mounted. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 1857 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. For additional information, refer to Fuel Delivery and Air Induction. 2. Disconnect the electrical connector. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down while rotating the sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. 3. Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the system. For additional information, refer to Evaporative Emission System Leak Test. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Service and Repair Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation > General Intake Air Temperature Sensor: Description and Operation General The IAT sensor: ^ sends the PCM a signal indicating the temperature of the air entering the engine. ^ resistance decreases as temperature increases. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation > General > Page 1863 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors are thermistor devices in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and 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. Diagram Of Flow Through Throttle Body (Containing IAT Sensor Wire Where Applicable) Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. 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 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation > General > Page 1864 to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT sensor. Supercharged 5.4L Lightning vehicles use (2) IAT sensors. Both sensors operate as described above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation > Page 1865 Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 2. Remove the IAT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock sensor 13 - 16 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > General Knock Sensor: Description and Operation General The system has a unique linear KS located in the lifter valley. ^ The KS sends a signal to the PCM indicating engine detonation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > General > Page 1871 Knock Sensor: Description and Operation Knock Sensor Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 1872 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. For additional information, refer to Engine. 2. Remove the Knock Sensor (KS). 1 Disconnect the electrical connector. 2 Remove the nut and the KS. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications Oil Pressure Sensor: Specifications Oil Pressure sensor 107 - 142 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature The Engine Oil Temperature (EOT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and 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. Engine Coolant Temperature (ECT) Sensor The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the Engine Coolant Temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1883 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1884 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1885 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1886 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1887 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1888 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1889 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1890 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1891 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1892 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1893 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1894 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1895 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1896 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 1897 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 1898 Heated Oxygen Sensor: Specifications Heated Oxygen Sensor 46 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 1899 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1902 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1903 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1904 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1905 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1906 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1907 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1908 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1909 Heated Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1910 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1911 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1912 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1913 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1914 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1915 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1916 Heated Oxygen Sensor: Connector Views Ford does not give the connector view. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 1917 Heated Oxygen Sensor: Application and ID 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 1918 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > General Heated Oxygen Sensor: Description and Operation General The HO2S: ^ has the ability to create a voltage signal dependent on exhaust oxygen content. ^ provides feedback information to the PCM used to calculate fuel delivery. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > General > Page 1921 Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor Heated Oxygen Sensor The Heated Oxygen Sensor (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 low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high 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. Heated Oxygen Sensor (HO2S) Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 1922 Heated Oxygen Sensor: Service and Repair EGO Sensor Wrench SPECIAL SERVICE TOOL(S) REMOVAL 1. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 2. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 3. Using the special tool, remove the HO2S. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 1923 EGO Sensor Wrench Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Bolts/Nuts 6 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Specifications > Page 1927 Pressure Feedback Exhaust Sensor: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Specifications > Page 1928 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Specifications > Page 1929 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback EGR Sensor Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor Differential Pressure Feedback 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 sensor receives this signal through two 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 aluminum 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. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback EGR Sensor > Page 1932 Pressure Feedback Exhaust Sensor: Description and Operation General The differential pressure feedback EGR sensor: ^ monitors the EGR flow rate through the EGR valve tube. ^ sends an EGR flow rate signal to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 1933 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the bolts and remove the engine appearance cover (if equipped). NOTE: The 4.6L engine is shown, the 5.4L engines are similar. 3. Remove the differential pressure feedback EGR. 1 Disconnect the electrical connector. 2 Disconnect the hoses. 3 Remove the bolts (nuts if applicable). INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > General Throttle Position Sensor: Description and Operation General The TP sensor: ^ sends the PCM a signal indicating the throttle plate angle. ^ is the main input to the PCM from the driver. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > General > Page 1939 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (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 three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 1940 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the bolts and the accelerator splash shield. 2. Disconnect the Throttle Position (TP) sensor electrical connector. 3. Remove the screws and the TP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission TR Sensor 71 - 88 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 1944 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > 4R70W Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > 4R70W > Page 1947 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 1948 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 1949 Digital Transmission Range Sensor: Service and Repair Special Tools Removal 1. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If this concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 1950 5. Remove the digital Transmission Range (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. Installation 1. Install the digital Transmission Range (TR) sensor. 1 Install digital Transmission Range (TR) sensor. 2 Loosely install the bolts. 2. Note: Make sure that the manual control lever is in the neutral position. Install the TRS Alignment Gauge. The TRS Alignment Gauge is designed to fit snug. 3. Tighten the bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 1951 4. Reconnect the shift cable at the manual control lever. 5. Reconnect the connector. 6. Lower the vehicle. 7. Reconnect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > General Vehicle Speed Sensor: Description and Operation General The VSS: ^ is gear driven by the transmission. ^ sends a signal to the PCM indicating vehicle speed. For additional information, refer to Automatic Transmission/Transaxle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > General > Page 1956 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Vehicle Speed Sensor Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission transaxle shift scheduling and torque converter clutch scheduling. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Bolts/Nuts 6 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 1961 Pressure Feedback Exhaust Sensor: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 1962 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 1963 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback EGR Sensor Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor Differential Pressure Feedback 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 sensor receives this signal through two 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 aluminum 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. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback EGR Sensor > Page 1966 Pressure Feedback Exhaust Sensor: Description and Operation General The differential pressure feedback EGR sensor: ^ monitors the EGR flow rate through the EGR valve tube. ^ sends an EGR flow rate signal to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 1967 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the bolts and remove the engine appearance cover (if equipped). NOTE: The 4.6L engine is shown, the 5.4L engines are similar. 3. Remove the differential pressure feedback EGR. 1 Disconnect the electrical connector. 2 Disconnect the hoses. 3 Remove the bolts (nuts if applicable). INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow (MAF) Sensor Plate Nuts 10 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 1972 Mass Air Flow Sensor: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 1973 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 1974 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 1975 Mass Air Flow Sensor: Service Precautions CAUTION: ^ Do not tamper with the sensing elements located in the Mass Air Flow (MAF) sensor. Tampering may result in unit failure. ^ The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > General Mass Air Flow Sensor: Description and Operation General The MAF sensor: ^ sends the PCM a signal indicating mass airflow rate of air entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > General > Page 1978 Mass Air Flow Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (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 ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass 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. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > Page 1979 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Open the air cleaner. ^ Disconnect the MAF sensor extension harness connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the air cleaner from the outlet side of the air cleaner. CAUTION: Do not tamper with the sensing elements located in the Mass Air Flow (MAF) sensor. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and serviced as a unit. 2. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. 3. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > Page 1980 4. Remove the MAF sensor plate and the MAF sensor from the outlet side of the air cleaner. 5. Disconnect the MAF sensor electrical connector from the extension harness. 6. Separate the MAF sensor plate from the MAF sensor. ^ Remove the nuts from the MAF sensor plate. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to correctly align the inlet side and the outlet side of the air cleaner. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine Fuel Temperature Sensor The Engine Fuel Temperature (EFT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Fuel Temperature (EFT) Sensor The EFT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Description and Operation Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off 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 Guide for the location of the IFS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > General Throttle Position Sensor: Description and Operation General The TP sensor: ^ sends the PCM a signal indicating the throttle plate angle. ^ is the main input to the PCM from the driver. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > General > Page 1992 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (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 three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 1993 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the bolts and the accelerator splash shield. 2. Disconnect the Throttle Position (TP) sensor electrical connector. 3. Remove the screws and the TP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft position sensor bolt 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 1998 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > General Camshaft Position Sensor: Description and Operation General The CMP sensor: ^ sends the PCM a signal indicating camshaft position used for fuel synchronization. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > General > Page 2001 Camshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 2002 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft position sensor bolt 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2006 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (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 Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 2009 Crankshaft Position Sensor: Description and Operation Engine Ignition The CKP sensor: ^ is a variable reluctance sensor. ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. ^ provides base timing and crankshaft speed (rpm) to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 2010 Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 2011 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the A/C compressor. For additional information, refer to Heating and Air Conditioning. 2. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 2017 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 2018 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 2019 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 2020 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 2021 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock sensor 13 - 16 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > General Knock Sensor: Description and Operation General The system has a unique linear KS located in the lifter valley. ^ The KS sends a signal to the PCM indicating engine detonation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > General > Page 2027 Knock Sensor: Description and Operation Knock Sensor Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Page 2028 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. For additional information, refer to Engine. 2. Remove the Knock Sensor (KS). 1 Disconnect the electrical connector. 2 Remove the nut and the KS. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Side Crash Sensor Screws 12 Nm Restraint Control Module (RCM) Bracket Screws 12 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor Impact Sensor: Locations Driver Side Air Bag Crash Sensor Near driver seat. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 2035 Impact Sensor: Locations Passenger Side Air Bag Crash Sensor Near passenger seat. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 2036 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 2037 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 2038 Impact Sensor: Service and Repair REMOVAL AND INSTALLATION WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ Right side is shown, left side is similar. ^ The side crash sensors are located under the carpet beneath the front seats. 1. Disconnect the battery ground cable and wait at least one minute. 2. Position the side crash sensor out from under the seat. 1 Pull the carpet flap out from under the outboard side of the seat to expose the side crash sensor. 2 Remove the pin-type retainer. 3 Remove the bolts. 4 Position the side crash sensor out from under the seat. NOTE: A flap opening in the carpet, at the outboard side of the front seats already exists, for servicing the side crash sensor. 3. Remove the side crash sensor. 1 Disconnect the electrical connector. 2 Remove the side crash sensor and bracket. 4. To install, reverse the removal procedure. WARNING: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 2039 ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR CORRECT SYSTEM OPERATION. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 5. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Description and Operation Safing Sensor: Description and Operation The safing sensor is internal to the Restraints Control Module (RCM) and is not repaired separately. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation The Clutch Pedal Position (CPP) switch is controlled by the clutch pedal. Depressing the clutch pedal manually closes the CPP switch and allows engine cranking. The CPP switch will also deactivate the speed control system. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 2052 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 2053 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 2054 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 2055 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 2056 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > 4R70W Transmission Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > 4R70W Transmission > Page 2062 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Front Height Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Front Height Sensor > Page 2073 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Rear Ride Height Sensor: Service and Repair Rear Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Note: The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. Remove the air suspension height sensor. 1. Disconnect the electrical connector. 2. Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Rear > Page 2076 Ride Height Sensor: Service and Repair 4-Wheel System Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Note: The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. Remove the air suspension height sensor. 1. Disconnect the electrical connector. 2. Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications Suspension Mode Switch: Specifications Air Suspension Switch Bracket Mounting Bolt .................................................................................................................. 10.2-13.8 Nm (91-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair > Rear Only System Suspension Mode Switch: Service and Repair Rear Only System Removal 1. Disconnect the battery ground cable. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. 4. Disconnect the air suspension switch electrical connector. 5. Remove the air suspension switch bracket mounting bolt. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair > Rear Only System > Page 2085 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair > Rear Only System > Page 2086 Suspension Mode Switch: Service and Repair 4-Wheel System Removal 1. Disconnect the battery ground cable. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. 4. Disconnect the air suspension switch electrical connector. 5. Remove the air suspension switch bracket mounting bolt. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair > Rear Only System > Page 2087 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation Transmission Control Switch Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 2093 Transmission Mode Switch: Service and Repair Removal 1. Remove the Transmission Control (TC) switch. 1 Remove the TC switch cover. 2 Remove the TC switch. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission TR Sensor 71 - 88 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 2097 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > 4R70W Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > 4R70W > Page 2100 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 2101 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 2102 Digital Transmission Range Sensor: Service and Repair Special Tools Removal 1. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If this concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 2103 5. Remove the digital Transmission Range (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. Installation 1. Install the digital Transmission Range (TR) sensor. 1 Install digital Transmission Range (TR) sensor. 2 Loosely install the bolts. 2. Note: Make sure that the manual control lever is in the neutral position. Install the TRS Alignment Gauge. The TRS Alignment Gauge is designed to fit snug. 3. Tighten the bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 2104 4. Reconnect the shift cable at the manual control lever. 5. Reconnect the connector. 6. Lower the vehicle. 7. Reconnect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 71 - 88 in.lb Turbine Shaft Speed (TSS) Sensor Bolt 71 - 88 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 2108 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Output Shaft Speed (OSS) Sensor > Page 2111 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 2112 Transmission Speed Sensor: Service and Repair Removal 1. Remove the drive shaft. 2. Remove the rear transmission mount nuts. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Remove the rear transmission mount. 1 Raise the transmission up off the rear crossmember support. 2 Remove the bolts. 3 Remove the rear transmission mount. 4. Lower the transmission to gain access to the Turbine Shaft Speed (TSS) sensor, and the Output Shaft Speed (OSS) sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 2113 5. Remove the Turbine Shaft Sensor (TSS). 1 Remove the bolt. 2 Remove the Turbine Shaft Sensor (TSS). 6. Remove the Output Shaft Speed (OSS) sensor. 1 Remove the bolt. 2 Remove the Output Shaft Speed (OSS) sensor. Installation 1. Install the Output Shaft Speed (OSS) sensor. 1 Lubricate the O-ring and install the Output Shaft Speed (OSS) sensor. 2 Install the bolt. 2. Install the Turbine Shaft Sensor (TSS). 1 Lubricate the O-ring and install the Turbine Shaft Sensor (TSS). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 2114 2 Install the bolt. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the sensors will occur. Install the rear transmission mount. 1 Raise the transmission up. 2 Install the rear transmission mount. 3 Install the bolts. 4. Lower the transmission on to the rear crossmember support. 5. Install the rear transmission mount nuts. 6. Install the drive shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 2119 Four Wheel Drive Selector Switch: Description and Operation 4x4 Mode Switch Typical 4x4 Switch The Generic Electronic Module (GEM) provides the PCM with an indication of 4x4L. This input is used to adjust the shift schedule. A 5.0 volt module pull-up indicates 4x4H or 4x2. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 2120 Four Wheel Drive Selector Switch: Service and Repair Removal 1. Remove the center instrument panel trim panel. 2. Remove the shift range selector switch. 1 Remove the switch knob. 2 Disconnect the electrical connector. 3 Remove the bolts. 4 Remove the shift range selector switch. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications Output Speed Sensor Bolt 44 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Front Output Shaft Speed Sensor Speed Sensor: Service and Repair Front Output Shaft Speed Sensor Removal 1. Remove the transfer case shift motor. 2. Remove the wire connector spacer and the front output shaft speed sensor wire pins from the electrical connector. - Use the proper electrical connector pin remover. 3. Remove the front output shaft speed sensor. 1 Remove the bolt. 2 Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats net against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Front Output Shaft Speed Sensor > Page 2126 Speed Sensor: Service and Repair Rear Output Shaft Speed Sensor Removal WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air spring, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the wire connector spacer and the rear output shaft speed sensor wire pins from the electrical connector. - Use the proper electrical connector pin remover. 4. Remove the bolt, and remove the sensor. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Front Output Shaft Speed Sensor > Page 2127 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams > Page 2132 Heated Glass Element Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the steering column opening cover. NOTE: Position the gear shifter into low or drive 1 position. 3. Remove the headlamp switch. For additional information, refer to Lighting and Horns. 4. Remove the instrument panel finish panel. 1 Remove the panel bolts. 2 Remove the instrument panel finish panel. 5. Disconnect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams > Page 2133 6. Remove the rear window defrost switch. ^ Remove the screws. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch Power Window Switch: Diagrams Power Window Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 2138 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 2139 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 2140 Power Window Switch: Diagrams Vent Window Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power window Switch Power Window Switch: Testing and Inspection Power window Switch Left Front Component Testing Procedure (Part 1 Of 2) Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 2143 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 2144 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 2145 Schematic Right Front Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 2146 Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 2147 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 2148 Power Window Switch: Testing and Inspection Rear Window Switch Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 2149 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Windshield Washer Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 2154 Windshield Washer Switch: Description and Operation The steering column switches consist of the: ^ multifunction switch, which controls the: ^ turn signal. ^ hazard flasher. ^ windshield wiper/washer. ^ rear wiper/washer. ^ headlamp dimmer/flash-to-pass. ^ ignition switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection Windshield Washer Switch: Testing and Inspection Initial Inspection 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2157 Windshield Washer Switch: Testing and Inspection Generic Electronic Module (GEM) DTC Index B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2158 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2159 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2160 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2161 P1836-P1891 Part 5 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2162 Windshield Washer Switch: Testing and Inspection GEM Active Command Index Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2163 Windshield Washer Switch: Testing and Inspection Generic Electronic Module (GEM) PID Index Part 1 of 3 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2164 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2165 Windshield Washer Switch: Testing and Inspection Initial Inspection 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Generic Electronic Module (GEM) DTC Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2166 B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2167 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2168 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2169 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2170 P1836-P1891 Part 5 of 5 GEM Active Command Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2171 Part 1 of 2 Part 2 of 2 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2172 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2173 Part 3 of 3 Component Tests Multifunction Switch Tests Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2174 Component Testing Procedure Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2175 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2176 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2177 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2178 Test A: No Communication With the Module-GEM Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2179 Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2180 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2181 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2182 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2183 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2184 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 2185 Windshield Washer Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Note: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 2186 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the multi function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the multi function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Wiper Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 2190 Wiper Switch: Description and Operation The steering column switches consist of the: ^ multifunction switch, which controls the: ^ turn signal. ^ hazard flasher. ^ windshield wiper/washer. ^ rear wiper/washer. ^ headlamp dimmer/flash-to-pass. ^ ignition switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection Wiper Switch: Testing and Inspection Initial Inspection 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2193 Wiper Switch: Testing and Inspection Generic Electronic Module (GEM) DTC Index B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2194 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2195 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2196 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2197 P1836-P1891 Part 5 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2198 Wiper Switch: Testing and Inspection Component Tests Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2199 Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2200 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2201 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2202 Wiper Switch: Testing and Inspection GEM Active Command Index Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2203 Wiper Switch: Testing and Inspection Initial Inspection 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Generic Electronic Module (GEM) DTC Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2204 B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2205 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2206 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2207 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2208 P1836-P1891 Part 5 of 5 Component Tests Multifunction Switch Tests Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2209 Component Testing Procedure Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2210 Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2211 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2212 Schematic GEM Active Command Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2213 Part 1 of 2 Part 2 of 2 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2214 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2215 Part 3 of 3 Test A: No Communication With the Module-GEM Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2216 Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2217 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2218 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2219 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2220 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 2221 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 2222 Wiper Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Note: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 2223 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the multi function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the multi function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications Alignment: Specifications Alignment Specifications General Alignment Specifications General Alignment Specifications General Alignment Specifications General Alignment Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 2229 Alignment: Specifications Ride Height Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 2230 Alignment: Specifications Torque Specifications Front Suspension Upper Arm Nuts .......................................................................................................................................... 113-153 Nm (84-112 ft. lbs.) Toe Set Jam Nuts ................................................................................................ ......................................................................... 77-104 Nm (57-77 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2231 Alignment: Description and Operation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2232 Caster and camber are adjusted by means of eccentric cams on the upper control arm mounting bolts. Toe is adjusted by the use of the front wheel spindle tie rod adjusting sleeve. The three basic alignment angles are camber, caster, and toe. Camber and toe affect tire wear and directional stability, caster affects directional stability only. Camber, caster and toe settings change when the vehicle is loaded. The specifications given are static settings with the vehicle unloaded. Camber is the inward or outward tilting of the wheels at the top. When the wheels tilt out at the top the camber is positive (+). When the wheels tilt in at the top the camber is negative (-). The amount of camber is measured in degrees from vertical. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2233 Steering axis inclination (included angle) is the center line drawn through the ball joints when viewed from the front. Caster is the tilting of the steering axis either forward or backward from vertical. A backward tilt is positive (+) and a forward tilt is negative Wheel Track Toe is a measurement of how much the front of the wheels are turned in or out from the straight-ahead position. When the wheels are turned in, toe is positive (+)(toe in). When the wheels are turned out, toe is negative (-)(toe out). Toe is measured in degrees, from side to side and totaled. Toe should only be checked and adjusted after the camber and caster have been set to the proper specifications. Dogtracking Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 2234 By design the vehicle has a front track that is wider at the front than the rear. Front track is the distance between the two front tires; rear track is the distance between the two rear tires. Dogtracking is the condition where the rear axle is not square to the chassis. Heavily crowned roads may give the illusion of dogtracking. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Alignment: Service and Repair Camber and Caster Adjustment 1. Loosen the upper suspension arm nuts to a point where the joints are snug. 2. Note: A pry bar can be used between the front suspension upper arm and the frame pocket to aid in moving the arm. To increase caster and camber, use the following steps. 1. To increase caster, move the front of the front suspension upper arm outboard and move the rear of the front suspension upper arm inboard. 2. To increase camber, move the front suspension upper arm outboard equally. 3. To decrease caster and camber, use the following steps. 1. To decrease caster, move the front of the front suspension upper arm inboard and move the rear of the front suspension upper arm outboard. 2. To decrease camber, move the front suspension on upper arm inboard equally. 4. Note: Each increment of the notches on the frame pocket represents 0.3 degree. Set the caster and camber to specifications. If a caster increase of 0.9 degree is required, move the front of the front suspension upper arm outboard by 3 notches and move the rear of the front suspension upper arm inboard by 3 notches. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2237 5. Tighten the upper suspension arm nuts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2238 Alignment: Service and Repair Ride Height RIDE HEIGHT Adjustment Note: For Four Wheel Air Suspension (4WAS) equipped vehicles, the front air shocks need to be vented before measuring or adjusting ride height. 1. Vent the front air shocks. - Using the scan tool, select AIR SUSPENSION CONTROL MODE under the ACTIVE COMMAND MODES menu. Select VENT FRNT command to deflate the front air shocks down. Hold for 30 seconds to allow complete system venting. Do not disconnect the scan tool. Keep it at the same mode as specified to keep the system at diagnostic mode at time of ride height measurement. If the scan tool is disconnected, the system will go to the operational mode and based on signal inputs, will level the vehicle to specified height (trim or kneel). 2. Raise and support the vehicle. - Use a hoist with frictionless plates to support the front wheels. - Normalize the vehicle static ride height. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2239 3. Measure the front suspension from the center line on the nut side of the front bolt on the front suspension lower arm to the ground, and record. 4. Measure the front suspension from the bottom of the front wheel knuckle to the ground, and record. Note: The ride height specification for base vehicles with new suspension components is higher than the specification for vehicles using original suspension components to allow for new component settling. 5. To obtain the front suspension ride height, subtract the measurement in Step 3 from the measurement in Step 2. - If the measurement is out of specification, ride height adjustment is required. 6. Note: For the front ride height setting procedure on vehicles equipped with Four-Wheel Air Suspension (4WAS) system, refer to Electronic Level Control. See: Steering and Suspension/Suspension/Suspension Control ( Automatic - Electronic ) Note: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2240 - Use only hand tools for this adjustment. - The ride height measurement on the opposite side from the adjustment may change. Adjust the ride height by tightening or loosening the torsion bar adjusting bolt. Inspect the ride height on both sides after each adjustment. 7. Note: Do not under any circumstances "save rear" ride heights - there are precalibrated values already stored in the control module. Once the mechanical ride heights are set, using the scan tool, select SAVE CALIBRATION VALUES under ACTIVE COMMAND MODE menu to calibrate the module. Trigger through warning message and save FRONT (turn from OFF to ON). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2241 Alignment: Service and Repair Toe Adjustment 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the "straightforward" position by attaching a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings; follow the equipment manufacturer's instructions. 4. Hold the tie-rod end while loosening the toe set jam nuts. 5. Rotate the front wheel spindle tie-rod adjusting sleeve to desired position. 6. Note: Whenever the toe set jam nuts are loosened for toe adjustment, the nut and tie-rod threads must be cleaned and lubricated. Tighten the jam nuts as follows: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 2242 1. Make sure the inner and outer ball joint sockets are perpendicular to the ball studs. 2. Hold the adjuster sleeve in position with locking pliers positioned against the lower control arm. 3. Tighten one adjuster sleeve jam nut to the specified torque. 4. Make an alignment mark across the adjuster sleeve and the tightened jam nut. Make a second mark across the jam nut and the tie-rod end threads. 5. Tighten the remaining jam nut. 6. Check the alignment marks. If either mark is out of alignment, check the toe setting. Readjust, if necessary, and repeat these steps. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve 7.75 Nm Fuel Pressure Relief Valve Cap 0.6 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 2248 Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 700 - 760 RPM Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Locations > Page 2256 Air Filter Element: Service Precautions CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Locations > Page 2257 Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet Air Cleaner (ACL) aside. 2. Remove the (A) Air Cleaner (ACL) element from the (B) open end of the inlet air cleaner. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure the tabs are aligned properly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD . Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2262 Fuel Pressure Release: Service and Repair SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. ^ This will drain some fuel out of the system. Place the fuel in a suitable container. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2263 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications V8 Firing Order: 1 3 7 2 6 5 4 8 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 2267 Firing Order: Locations V8 Firing Order: 1 3 7 2 6 5 4 8 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plugs 9-20 Nm Original Spark Plug AWSF22E Replacement Spark Plug AWSF22E Spark Plug Gap 1.32-1.42 mm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 2276 Spark Plug: Specifications Spark Plugs 9-20 Nm Original Spark Plug AWSF22E Replacement Spark Plug AWSF22E Spark Plug Gap 1.32-1.42 mm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2277 Spark Plug: Application and ID Original Spark Plug Type ..................................................................................................................... ............................................................... AWSF22E Replacement Spark Plug Type .......................... ................................................................................................................................................... AWSF22E Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2278 Spark Plug: Description and Operation The spark plugs: ^ change a high voltage pulse into a spark which ignites the fuel and air mixture. ^ originally equipped on the vehicle have a platinum-enhanced electrode for long life. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal and Installation Spark Plug: Service and Repair Removal and Installation SPARK PLUG Engine Ignition - RH Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal and Installation > Page 2281 Engine Ignition - LH Exploded View Material Removal and Installation See TSB 8-1-9 Jan. 2008 1. Disconnect the ignition coil electrical connector. 2. NOTE: When removing the ignition coils, a slight twisting motion will break the seal and ease removal. Remove the bolt and the ignition coil. 3. NOTICE: Do not remove the spark plugs when the engine is hot or cold soaked. Spark plug thread or cylinder head damage can occur. Make sure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal and Installation > Page 2282 the engine is warm (hand touch after cooling down) prior to spark plug removal. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. Remove the spark plug in the following sequence. (1).Loosen the spark plug no more than one-eighth to one-fourth of a turn. (2).NOTICE: Excessive use of carburetor tune-up cleaner can introduce enough liquid volume to hydro-lock the engine. Using carburetor tune-up cleaner, fill the spark plug well until fluid has reached the spark plug jamb nut. Follow the directions on the packaging. (3).NOTICE: Do not loosen or tighten the spark plug for a minimum of 15 minutes or damage to the cylinder head or spark plug may occur. Let the carburetor tune-up cleaner soak for a minimum of 15 minutes. (4).NOTE: Some screeching and high effort may be noticed and is normal. NOTE: The expected removal torque is around 45 Nm (33 lb-ft). Tighten, and then loosen the spark plug, repeating until turning effort is reduced, and remove the spark plug. 4. Inspect the spark plug. Install a new spark plug as necessary. Installation 1. NOTICE: The spark plug gap is NOT adjustable. Damage can occur to the ceramic if the spark plug gap is adjusted. Install a new spark plug if the gap is out of specification. NOTE: Refer to the specifications in this section for correct spark plug identification. NOTE: Do not apply high temperature nickel anti-seize lubricant to the spark plug ground strap area. Apply high temperature nickel anti-seize lubricant to only the spark plug ground electrode shield as shown. 2. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. Install the spark plug. To install, tighten to 34 Nm (25 lb-ft). 3. NOTE: Verify that the ignition coil spring is correctly located inside the ignition coil-on-plug boot and that there is no damage to the tip of the boot. Install the ignition coil and the bolt. Apply a light coat of dielectric compound to the inside of the ignition coil boots. To install, tighten to 6 Nm (53 lb-in). 4. Connect the ignition coil electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal and Installation > Page 2283 Spark Plug: Service and Repair Spark Plug - Inspection REMOVAL 1. Remove the coil on plugs. For additional information refer to Ignition Coil. 2. Remove the spark plugs. NOTE: Remove any foreign material from the spark plug wells with compressed air before removing the spark plugs. 3. Inspect the spark plugs. For additional information, refer to Engine. 4. Adjust the spark plug gap as necessary. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 within 75 percent of the highest reading. For additional information, refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2287 Compression Check: Testing and Inspection General Remarks Note: Removing fuses and disconnecting electrical components causes the Powertrain Control Module (PCM) to log an error message. After the measurements have been carried out this error message should be cleared from memory by connecting to PDU. Note: Only check the compression pressure with the valves set to the prescribed clearance (if this can be adjusted). The compression pressure should be checked with the engine at operating temperature. Check The Compression Pressure WARNING: On manual transmissions shift the transmission into neutral. On automatic transmission vehicles, select "P". Failure to follow these instructions may result in personal injury. 1. Remove the fuel pump relay. 2. Start the engine-the engine will start, run for a few seconds then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter switch in the starting circuit. With the ignition switch OFF, using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 6. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 7. Install the components in reverse order, observing the specified tightening torques. 8. Reset the PCM fault memory. Interpretation of the Results The indicated compression pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading. CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent damage to the catalytic converter. If the measurement on one or more cylinders is much lower than the specified value, spray some engine oil into the combustion chamber and repeat the compression measurement. If the reading greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other arc both too low then it is very likely that the cylinder head gasket between them is burnt through. This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer does not indicate whether this vehicle has adjustable or non-adjustable valves. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations Drive Belt: Locations Accessory Drive 4.6L, 5.4L(2V), 5.4L(4V) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations > Page 2294 Drive Belt: Diagrams Accessory Drive 4.6L, 5.4L(2V), 5.4L(4V) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations > Page 2295 Drive Belt: Description and Operation Accessory Drive 4.6L, 5.4L(2V), 5.4L(4V) The accessory drive consists of the: - drive belt (8620). - generator pulley. - power steering pump pulley. - crankshaft pulley. - A/C clutch pulley. - belt idler pulley. - drive belt tensioner. - water pump pulley. The accessory drive: - has a single serpentine drive belt. - has an automatic drive belt tensioner. - does not require adjustment. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview 1. Verify customer concern by running the engine. 2. Inspect the drive belt for chunking, fraying and wear. 3. Check the drive belt for correct routing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2299 Drive Belt: Component Tests and General Diagnostics Belt Tension Note: Drive belt tension is not adjustable. The drive belt tensioner automatically adjusts drive belt tension. Belt Tensioner, Automatic Check the automatic drive belt tensioner: 1. With the engine off, check for proper drive belt routing. Service as required. 2. Rotate the drive belt tensioner and check for a binding or frozen condition. Replace components as required. V-Ribbed Belt With Cracks (Acceptable) V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable) Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys. Non-standard replacement drive belts may track differently or improperly. If a replacement drive belt tracks improperly, replace it with an original equipment drive belt to avoid performance failure or loss of drive belt. With the engine running, check drive belt tracking. If the (A) edge of the drive belt rides beyond the edge of the pulleys, noise and premature wear may occur. Make sure the (B) drive belt rides correctly on the pulley. If a drive belt tracking condition exists, proceed with the following: Visually check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. This will result in chirp and squeal noises. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2300 - With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the pulley forward faces) for excessive wobble. Replace components as required. - Check all accessories, mounting brackets and the drive belt tensioner for any interference that would prevent the component from mounting properly. Correct any interference condition and recheck the drive belt tracking. - Tighten all accessories, mounting brackets, and drive belt tensioner retaining hardware to specification. Recheck the drive belt tracking. Drive Belt Noise/Flutter Note: Tensioner is shown in free-state position against arm travel stops. Drive Belt Tensioner/Belt Length Indicator Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged pulley or an improperly aligned pulley. To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a straightedge to the crankshaft pulley, look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge. Drive belt squeal is an intermittent noise that occurs when the drive belt slips on a pulley during certain conditions, such as: engine start up, rapid engine acceleration, or A/C clutch engagement. Drive belt squeal can occur under certain conditions: If the A/C discharge pressure goes above specifications: + the A/C system is overcharged. + the A/C condenser core airflow is blocked. - If the A/C OFF equalized pressure (the common discharge and suction pressure that occurs after several minutes) exceeds specifications. - If any of the accessories are damaged, have a worn or damaged bearing, internal torsional resistance above normal. All accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory. - If fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air conditioning system lubricant. If fluid does get on the drive belt during service, clean the drive belt with soap and water and thoroughly rinse with clean water. The drive belt does not have to be Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2301 replaced if no apparent damage has occurred. - Note: The drive belt tensioner arm should rotate freely without binding. If the drive belt is too long. A drive belt that is too long will allow the drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. If the drive belt tensioner indicator is outside the installation wear range window, replace the drive belt. - If the drive belt tensioner is worn or damaged. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 2302 Drive Belt: Adjustments Note: Drive belt tension is not adjustable. The drive belt tensioner automatically adjusts drive belt tension. Belt Tensioner, Automatic Check the automatic drive belt tensioner: 1. With the engine off, check for proper drive belt routing. Service as required. 2. Rotate the drive belt tensioner and check for a binding or frozen condition. Replace components as required. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 2303 Drive Belt: Service and Repair Accessory Drive Removal 4.6L, 5.4L(2V), 5.4L(4V) 1. Rotate the drive belt tensioner clockwise and remove the drive belt. Installation 4.6L, 5.4L(2V), 5.4L(4V) 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Locations > Page 2309 Air Filter Element: Service Precautions CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Locations > Page 2310 Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet Air Cleaner (ACL) aside. 2. Remove the (A) Air Cleaner (ACL) element from the (B) open end of the inlet air cleaner. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure the tabs are aligned properly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD . Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2318 Fuel Pressure Release: Service and Repair SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. ^ This will drain some fuel out of the system. Place the fuel in a suitable container. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2319 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil filter 11 - 12 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Specifications Coolant Line/Hose: Specifications Water outlet connection bolts 18 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2335 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2336 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2342 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2343 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 2344 Heater Hose: Specifications Junction block bracket screw 12 Nm Starter relay cable nut 8 Nm Starter relay cable ends 8 Nm Hose Clamp 1.6 - 2.2 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 2345 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 2346 Heater Hose Coupler Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 2347 Heater Hose: Service Precautions WARNING: THE ENGINE MUST BE OFF, FULLY COOL AND THE COOLING SYSTEM FULLY DEPRESSURIZED BEFORE ATTEMPTING TO DISCONNECT ANY HEATER WATER HOSES. FAILURE TO COMPLY WITH THIS WARNING CAN RESULT IN SERIOUS INJURY OR BURNS FROM HOT LIQUID ESCAPING OUT OF THE ENGINE COOLING SYSTEM. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 2348 Heater Hose: Description and Operation Refrigerant Lines: Part 1 0f 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 2349 Refrigerant Lines: Part 2 Of 2 The auxiliary lines are two-piece tubes that are secured to the underbody of the vehicle. New auxiliary line kits are only available with multiple-piece lines for ease of installation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control Heater Hose: Service and Repair Auxiliary Climate Control Line - Front Auxiliary Heater Outlet and Inlet Refrigerant Lines: Part 1 0f 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2352 Refrigerant Lines: Part 2 Of 2 REMOVAL NOTE: The front auxiliary heater outlet line is shown; the front auxiliary heater inlet line is similar. 1. Drain the cooling system. For additional information, refer to Cooling System. 2. Turn the air suspension switch off, if equipped. 3. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 4. Remove the wheel and tire assembly. For additional information, refer to Wheels,Tires and Alignment. 5. Loosen the RH front fender splash shield. 1 Remove the bolts. 2 Remove the pin-type retainers. 3 Move the front fender splash shield to access the lines. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2353 6. Remove the three line bracket retaining nuts. 7. Remove the three line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 8. Disconnect the heater outlet line from the outlet hose coupling. 9. Disconnect the front auxiliary heater outlet line from the rear auxiliary heater outlet line. 1 Remove the nut. 2 Disconnect the line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2354 10. Cut the heater outlet line where it crosses under the frame. 11. Cut the heater outlet line near the front wheel well opening. 12. Remove and discard the cut sections. INSTALLATIONS NOTE: Refer to the Multiple-Piece Auxiliary A/C Heater Line Kit illustration in Description and Operation. 1. Install the heater outlet line. ^ Install the end with the blue tape over the frame. 2. Connect the heater outlet line peanut fitting. 1 Connect the fitting. 2 Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2355 3. Install the heater outlet line. ^ Install the end with the red tape over the frame. ^ Install the end with the yellow tape between the frame and the body vertical flange. NOTE: View shown with fender skirt removed for clarity. 4. Connect the heater water outlet line to the heater water outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fitting. 2 Loosely install the nut. 5. Install the heater water outlet line to the heater water outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. ^ Install the line through the wheel opening. NOTE: Fender skirt removed for clarity. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2356 6. Connect the heater water outlet line to the heater water outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fitting. 2 Loosely install the nut. 7. Tighten the three peanut fittings. 8. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: ^ Verify that clearance exists between the frame and the lines to prevent component damage. ^ Overtightening of the nut will cause the stud to break away from the floorpan. NOTE: The bracket must be positioned equally between the white location marks on the line. 9. Connect the heater water outlet line to the engine heater outlet hose coupling. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2357 10. Install the bolts, the pin-type retainers and the front fender splash shield. 11. Install the wheel and tire assembly. For additional information, refer to Wheels,Tires and Alignment. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Fill the cooling system. For additional information, refer to Cooling System. Inlet Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2358 Refrigerant Lines: Part 1 0f 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2359 Refrigerant Lines: Part 2 Of 2 REMOVAL 1. Drain the cooling system. For additional information, refer to Cooling System. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater inlet hose coupling. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2360 7. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 8. Lower the muffler heat shield. 1 Remove the two front bolts. 2 Lower the heat shield. 9. Remove the four line bracket retaining nuts. 10. Remove the four line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 11. Disconnect the inlet line peanut fitting. 1 Remove the nut. 2 Disconnect the line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2361 12. Cut the heater inlet line near the A/C line grommet. 13. Cut the heater inlet line near the rear crossmember. 14. Cut the heater inlet line between the frame and the muffler heat shield. 15. Remove and discard the cut sections. INSTALLATION NOTE: ^ Lay out new lines in vehicle position to assist in installation. ^ Refer to the Multiple-Piece Auxiliary A/C Heater Line Kit illustration in Description and Operation. 1. Install the heater inlet line. ^ Starting from the rear of the vehicle, install the end with the green tape over the rear axle between the frame crossmember and the body. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2362 2. Connect the heater inlet line peanut fitting. 1 Connect the inlet lines. 2 Loosely install the nut. 3. Install the heater inlet line. ^ Starting from the rear of the vehicle, install the end with the blue tape between the frame crossmember and the floor pan. 4. Connect the heater inlet line to the heater inlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fittings. 2 Loosely install the nut. 5. Install the heater inlet line. 1 Remove the RH rear wheel and tire. 2 Install the end with the red tape between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2363 6. Connect the heater inlet line to the heater inlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fittings. 2 Loosely install the nut. 7. Install the heater inlet line. ^ Install the end with the green tape through the floor opening. 8. Connect the heater inlet line to the heater inlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fittings. 2 Loosely install the nut. 9. Tighten the four peanut fittings. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2364 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floor pan. NOTE: The bracket must be positioned equally between the white location marks on the line. 11. Install the muffler heat shield. 1 Position the shield. 2 Install the nuts. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 15. Connect the heater inlet hose coupling. 16. Install the quarter trim access panel. 17. Install the spare tire. 18. Fill the cooling system. For additional information, refer to Cooling System. Outlet Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2365 Refrigerant Lines: Part 1 0f 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2366 Refrigerant Lines: Part 2 Of 2 REMOVAL 1. Drain the cooling system. For additional information, refer to Cooling System. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater outlet hose coupling. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2367 7. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 8. Lower the muffler heat shield. 1 Remove the two front bolts. 2 Lower the heat shield. 9. Remove the four line bracket retaining nuts. 10. Remove the four line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 11. Disconnect the outlet line peanut fitting. 1 Remove the nut. 2 Disconnect the line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2368 12. Cut the heater outlet line near the grommet. 13. Cut the heater outlet line near the rear crossmember. 14. Cut the heater outlet line between the frame and the muffler heat shield. 15. Remove and discard the cut sections. INSTALLATION NOTE: ^ Lay out new lines in vehicle position to assist in installation. ^ Refer to the Multiple-Piece Auxiliary A/C Heater Line Kit illustration in Description and Operation. 1. Install the heater outlet line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2369 ^ Starting from the rear of the vehicle, install the end with the blue tape over the axle between the frame and the body. 2. Connect the heater outlet line peanut fitting. 1 Connect the outlet lines. 2 Loosely install the nut. 3. Install the heater outlet line. ^ Starting from the rear of the vehicle, install the end with the red tape between the frame and the floor pan. 4. Connect the heater outlet line to the heater outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fittings. 2 Loosely install the nut. 5. Install the heater outlet line. 1 Remove RH rear wheel and tire. 2 Install the end with blue tape between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2370 6. Connect the heater outlet line to the heater outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fittings. 2 Loosely install the nut. 7. Install the heater outlet line. ^ Install the end with the hose through the floor opening. 8. Connect the heater outlet line to the heater outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fittings. 2 Loosely install the nuts. 9. Tighten the four peanut fittings. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2371 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floorpan. NOTE: The bracket must be positioned equally between the white location marks on the line. 11. Install the muffler heat shield. 1 Position the shield. 2 Install the nuts. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 15. Connect the heater outlet hose coupling. 16. Install the quarter trim access panel. 17. Install the spare tire. 18. Fill the cooling system. For additional information, refer to Cooling System. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2372 Heater Hose: Service and Repair Heater Hose Coupling Disconnect Procedure Heater Hose Disconnect Tool SPECIAL SERVICE TOOL(S) DISCONNECT 1. Depressurize the engine cooling system. WARNING: THE ENGINE MUST BE OFF, FULLY COOL AND THE COOLING SYSTEM FULLY DEPRESSURIZED BEFORE ATTEMPTING TO DISCONNECT ANY HEATER WATER HOSES. FAILURE TO COMPLY WITH THIS WARNING CAN RESULT IN SERIOUS INJURY OR BURNS FROM HOT LIQUID ESCAPING OUT OF THE ENGINE COOLING SYSTEM. 2. Push the heater water hose toward the tube to fully expose the locking tabs. 3. Push the Heater Hose Disconnect Set over the coupling retainer windows to compress the retainer locking tabs. NOTE: When compressing the white coupling retainer, the Heater Hose Disconnect Set must be perpendicular to and on the highest point of the coupling. 4. Pull the heater water hose away from the heater core tube. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to assist in the removal. 5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2373 7. Spread the retainer tabs apart and slide the retainer off the tube. 8. Discard the retainer. CONNECT 1. Clean the tubes and lubricate with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESF-M99B112-A. 2. Install a new coupling retainer, spacer, and lubricated O-rings into the quick disconnect coupling housing. 3. Push the heater water hose with a quick disconnect coupling onto the tube. 4. Make sure the coupling is fully engaged by lightly pulling on the heater water hose. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2374 Heater Hose: Service and Repair Heater Hose Assembly REMOVAL 1. Drain the radiator. For additional information, refer to Cooling System. 2. Disconnect the heater outlet hose at the engine. 3. Disconnect the heater inlet hose at the engine. 1 Loosen the hose clamp. 2 Disconnect the heater inlet hose. 4. Disconnect the heater core hose couplings. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 2375 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Page 2376 Heater Hose Disconnect And Removal Tools Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Hose/Line HVAC Hose/Line HVAC: Specifications Peanut Fittings 6.8 - 9.2 Nm Peanut Fitting Expansion Vallve Refrigerant Lines 8 Nm Peanut Fitting Rear Heater Lines 8 Nm A/C Line Bracket Nuts 6.8 - 9.2 Nm A/C Evaporator To Expansion Valve Lines 12.7 - 17.3 Nm Outlet Line To Auxiliary Evaporator Case Line 8 Nm Front Auxiliary Heater Line Brackets 8 Nm Front Auxiliary A/C Line Bracket 8 Nm Front fender splash shield bolts 10.2-13.8 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Hose/Line HVAC > Page 2381 Hose/Line HVAC: Specifications Refrigerant Lines To Expansion Valve 12.7 - 17.3 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 2382 Hose/Line HVAC: Locations Refrigerant Lines: Part 1 0f 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 2383 Refrigerant Lines: Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 2384 Hose/Line HVAC: Service Precautions CAUTION: ^ Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. ^ Overtightening of the nut will cause the stud to break away from the floor pan. ^ Verify that clearance exists between the frame and the lines to prevent component damage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 2385 Hose/Line HVAC: Description and Operation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. The A/C manifold and tube is attached to the A/C compressor with O-ring seals and has the following features: ^ The upstream side contains low pressure refrigerant gas. ^ The downstream side contains high pressure refrigerant gas. ^ An integral non-serviceable muffler and a serviceable high pressure A/C charge port valve are located on the downstream side. ^ The downstream side also contains a fitting used to mount the A/C pressure cutoff switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure cutoff switch can be removed without discharging the A/C system. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control Hose/Line HVAC: Service and Repair Auxiliary Climate Control Front Auxiliary Evaporator Outlet and Inlet Line REMOVAL NOTE: The 5/8 inch front auxiliary evaporator outlet line is shown, the 3/8 inch front auxiliary evaporator inlet line is similar. 1. Recover the refrigerant from the system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Discharging and Recovery Procedure, See: Heating and Air Conditioning/Service and Repair/Refrigerant Discharging and Recovery procedure 2. Turn the air suspension switch off, if equipped. 3. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 5. Remove the RH front fender splash shield. 1 Remove the bolts. 2 Remove the pin-type retainers. 3 Remove the front fender splash shield. 6. Remove the three line bracket retaining nuts. 7. Remove the three line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2388 8. Disconnect the 5/8 inch auxiliary outlet line from the suction side of the A/C manifold and tube assembly. 1 Remove the nut. 2 Disconnect the line. 9. Disconnect the front auxiliary outlet line from the rear auxiliary line. 1 Remove the nut. 2 Disconnect the line. 10. Remove the front auxiliary evaporator outlet line. INSTALLATION 1. Install the front auxiliary evaporator outlet line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2389 2. Connect the front auxiliary outlet line to the rear auxiliary line. 1 Connect the outlet lines. 2 Loosely install the nut. 3 Snap the peanut fitting securely into the torque retention bracket. 3. Connect the front auxiliary outlet line to the suction side of the A/C manifold and tube assembly. 1 Connect the line. 2 Install the nut. 4. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floor pan. NOTE: The bracket must be positioned equally between the white location marks on the line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2390 5. Install the bolts, the pin-type retainers and the front fender splash shield. 6. Lower the vehicle. 7. Turn on the air suspension switch, if equipped. 8. Evacuate and charge the A/C system. Refer to: Heating and Air Conditioning, Service and Repair, Evacuation and Charging Procedure, See: Heating and Air Conditioning/Service and Repair/Evacuation and Charging Procedure Rear Auxiliary Evaporator Inlet Line Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2391 Refrigerant Lines: Part 1 0f 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2392 Refrigerant Lines: Part 2 Of 2 REMOVAL 1. Perform the Refrigerant Discharging and Recovery Procedure. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Discharging and Recovery Procedure, See: Heating and Air Conditioning/Service and Repair/Refrigerant Discharging and Recovery procedure 2. Remove the quarter trim panel access cover. 3. Disconnect the inlet line from the underbody line. 1 Remove the nut. 2 Remove the line. 4. Remove the auxiliary A/C lines grommet retainer. 1 Remove the bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2393 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 8. Remove the four line bracket retaining nuts. 9. Remove the four line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 10. Disconnect the inlet line peanut fitting. 1 Remove the nut. 2 Disconnect the line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2394 11. Cut the 3/8 inch evaporator inlet line near the A/C line grommet. 12. Cut the 3/8 inch evaporator inlet line near the rear crossmember. 13. Cut the 3/8 inch evaporator inlet line forward of the rear wheel opening. 14. Cut the 3/8 inch evaporator inlet line between the frame and the muffler heat shield. 15. Remove and discard the cut sections. INSTALLATION NOTE: Lay out new lines in vehicle position to assist in installation. 1. Install the inlet line. ^ Install the end with the hose over the rear axle between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2395 NOTE: Refer to the Multiple-Piece Auxiliary A/C Heater Line Kit illustration in Description and Operation. 2. Connect the inlet line peanut fitting. 1 Connect the inlet lines. 2 Loosely install the nut. 3 Snap the peanut fitting into the torque retention bracket. 3. Install the inlet line. ^ Starting from the rear of the vehicle, insert the end with the orange tape between the frame and the body. 4. Connect the inlet line to the inlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the inlet lines. 2 Loosely install the nut. 5. Install the inlet line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2396 1 Remove the RH rear wheel and tire. 2 Install the end with the yellow tape between the frame and the body. 6. Connect the inlet line to the inlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. ^ Connect the fitting and loosely install the nut. 7. Install the inlet line. ^ Install the end without tape through the floor. 8. Connect the inlet line to the inlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the line 2 Loosely install the nut. 9. Tighten the four peanut fittings. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2397 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floor pan. NOTE: The bracket must be positioned equally between the white location marks on the line. 11. Lower the vehicle. 12. Turn on the air suspension switch, if equipped. 13. Connect the inlet line to the auxiliary evaporator case line. 14. Install the grommet seal and retainer. NOTE: Make sure that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 15. Install the quarter trim access panel. 16. Evacuate and charge the A/C system. Refer to: Heating and Air Conditioning, Service and Repair, Evacuation and Charging Procedure, See: Heating and Air Conditioning/Service and Repair/Evacuation and Charging Procedure 17. Install the spare tire. Rear Auxiliary Evaporator Outlet Line Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2398 Refrigerant Lines: Part 1 0f 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2399 Refrigerant Lines: Part 2 Of 2 REMOVAL NOTE: Lay out new lines in vehicle position to assist in installation. 1. Perform the Refrigerant Discharging and Recovery Procedure. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Discharging and Recovery Procedure, See: Heating and Air Conditioning/Service and Repair/Refrigerant Discharging and Recovery procedure 2. Remove the quarter trim panel access cover. 3. Disconnect the outlet line from the underbody line. 1 Remove the nut. 2 Remove the line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2400 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 8. Lower the muffler heat shield. 1 Remove the two front nuts. 2 Lower the heat shield. 9. Remove the four line bracket retaining nuts. 10. Remove the four line brackets by inserting a screwdriver in the stud hole and twisting. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2401 CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 11. Disconnect the 5/8 inch outlet line peanut fitting that is located outboard of the side rail. 1 Remove the nut. 2 Disconnect the line. 12. Cut the 5/8 inch evaporator outlet line near the A/C line grommet. 13. Cut the 5/8 inch evaporator outlet line near the rear crossmember. 14. Cut the 5/8 inch evaporator outlet line forward of the rear wheel opening. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2402 15 Cut the 5/8 inch evaporator outlet line between the frame and the muffler heat shield. 16 Remove and discard the cut sections. INSTALLATION NOTE: ^ Lay out new lines in vehicle position to assist in installation. ^ Refer to the Multiple-Piece Auxiliary A/C Heater Line Kit illustration in Description and Operation. 1. Install the outlet line over the frame. ^ Install the end with violet tape between the frame and the body. 2. Connect the outlet line peanut fitting. 1 Connect the outlet lines. 2 Loosely install the nut. 3 Snap the peanut fitting into the torque retention bracket. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2403 3. Install the outlet line. ^ Starting from the rear of the vehicle install the end with the violet tape over the frame crossmember and between the main member and the muffler heat shield. 4. Connect the outlet line peanut fitting to the outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the outlet lines. 2 Loosely install the nut. 5. Install the outlet line. ^ Starting from the rear of the vehicle, install the end with the yellow tape between the frame and the muffler heat shield. 6. Connect the outlet line peanut fitting to the outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. ^ Connect the fitting and loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2404 7. Install the outlet line. 1 Remove the RH rear wheel and tire. 2 Install the end with the orange tape between the frame and the body through the rear wheel opening. 8. Connect the outlet line peanut fitting to the outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. ^ Connect the fitting and loosely install the nut. 9. Install the outlet line. ^ Install the end of the tube with no tape through the floor. 10. Connect the outlet line peanut fitting to outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. ^ Connect the fitting and loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2405 11. Tighten the five peanut fittings. 12. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floor pan. NOTE: The bracket must be positioned equally between the white location marks on the line. 13. Install the muffler heat shield. 1 Position the shield 2 Install the nuts. 14. Lower the vehicle. 15. Turn the air suspension switch on, if equipped. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2406 16. Connect the outlet line to the auxiliary evaporator case line. 17. Install the grommet seal and retainer. NOTE: Maker sure that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 18. Install the quarter trim access panel. 19. Evacuate and charge the A/C system. Refer to: Heating and Air Conditioning, Service and Repair, Evacuation and Charging Procedure, See: Heating and Air Conditioning/Service and Repair/Evacuation and Charging Procedure 20. Install the spare tire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2407 Hose/Line HVAC: Service and Repair Main Climate Control REMOVAL 1. Perform the Refrigerant Discharging and Recovery Procedure. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Discharging and Recovery Procedure, See: Heating and Air Conditioning/Service and Repair/Refrigerant Discharging and Recovery procedure 2. Disconnect the condenser to evaporator line spring lock coupling from the A/C evaporator core. 3. Disconnect the A/C condenser core lower line. 1 Remove the nut. 2 Disconnect the A/C condenser core lower line. 4. Remove the tube bracket nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 2408 5. Remove the suction accumulator/drier bracket clamp bolt. 6. Remove the evaporator to condenser tube. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seal with PAG Compressor Oil, YN-12c, F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 2. Evacuate and charge the A/C system. Refer to: Heating and Air Conditioning, Service and Repair, Evacuation and Charging Procedure, See: Heating and Air Conditioning/Service and Repair/Evacuation and Charging Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Page 2409 Spring Lock Coupling Disconnect Tool Set Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Power Steering Pressure Hose Fitting ............................................................................................................................................ 17-23 Nm (13-17 ft. lbs.) Power Steering Return Hose Fitting ............................................................................................................................................... 17-23 Nm (13-17 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Power Steering Low Pressure Power Steering Line/Hose: Service and Repair Hose - Power Steering Low Pressure Removal 1. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the power steering low pressure hose. Drain the power steering system. 3. Lower the vehicle. 4. Disconnect and remove the power steering low pressure hose. Installation 1. Follow the removal procedure in reverse order. 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Power Steering Low Pressure > Page 2415 Power Steering Line/Hose: Service and Repair Hose - Power Steering Pressure Special Tool(s) Removal 1. Prepare the vehicle for power steering pressure hose removal. 1. Remove the fan and shroud. 2. Remove the drive belt. 2. Disconnect the power steering pressure hose. Drain the power steering system. 3. Remove the power steering pump pulley using the Power Steering Pump Pulley Remover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Power Steering Low Pressure > Page 2416 4. Disconnect and remove the power steering pressure hose. Installation 1. Install a new seal on the power steering pressure hose at the power steering pump end. - Remove and discard the original seal. - Stretch the seal over the Seal Replacer until it is large enough to slip over the tube nut. 2. Route the power steering pressure hose in the vehicle. Connect the power steering pressure hose. 3. CAUTION: Replacement of the power steering pump pulley is necessary after being removed and installed two times. Install the power steering pump pulley. Inspect the pulley for paint marks in the web area near the hub. If there are two paint marks, replace the pulley. If there is no paint or one paint mark, use a paint pencil to mark the web area of the pulley near the hub. - Use the Power Steering Pump Pulley Replacer. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Power Steering Low Pressure > Page 2417 4. Connect the power steering pressure hose. 5. Restore the vehicle to operating condition. 1. Install the drive belt. 2. Install the fan and shroud. 3. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Power Steering Low Pressure > Page 2418 Power Steering Line/Hose: Service and Repair Hose - Power Steering Reservoir Pump Removal 1. Prepare the vehicle for power steering reservoir pump hose removal. 1. Remove the fan and shroud. 2. Remove the drive belt. 2. Remove the three bolts. 3. Disconnect the power steering reservoir pump hose. Drain the power steering system. 4. Remove the nuts and belt deflector. 5. Remove the two bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Power Steering Low Pressure > Page 2419 6. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in shifting of the vehicle during these operations. Raise and support the vehicle. 7. Disconnect the Electronic Variable Orifice (EVO) power steering control valve actuator electrical connector. 8. Remove the bolt. 9. Lower the vehicle. 10. Position the power steering pump forward. 11. Disconnect and remove the power steering reservoir pump hose. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Power Steering Low Pressure > Page 2420 Installation 1. Route the power steering reservoir pump hose in the vehicle. Connect the power steering reservoir pump hose. 2. Position the power steering pump. 3. Loosely install the bolts. 4. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in shifting of the vehicle during these operations. Raise and support the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Power Steering Low Pressure > Page 2421 5. Install the bolt. 6. Connect the EVO power steering control valve actuator electrical connector. 7. Lower the vehicle. 8. Tighten the bolts. 9. Install the belt deflector and nuts. 10. Connect the power steering reservoir pump hose. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Power Steering Low Pressure > Page 2422 11. Position the power steering pump reservoir. Install the three bolts. 12. Restore the vehicle to operating condition. 1. Install the drive belt. 2. Install the fan and shroud. 3. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Power Steering Low Pressure > Page 2423 Power Steering Line/Hose: Service and Repair Hose - Power Steering Return Removal 1. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the power steering return hose. Drain the power steering system. 3. Lower the vehicle. 4. Disconnect and remove the power steering return hose. Installation 1. Follow the removal procedure in reverse order. 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Brake Fluid High Performance DOT 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 2432 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Without Rear Aux. Heat 22.6 L With Rear Aux. Heat 24.9 L Without Rear Aux. Heat 24.1 L With Rear Aux. Heat 26.4 L Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 2435 Coolant: Fluid Type Specifications Antifreeze Type Ford Premium Engine Coolant (Green in color) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 2440 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 2441 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 4R100 ................................................................................................................... ........................................................................................................ 15.5L 4R70W .............................. .............................................................................................................................................................. .............................. 13.1L Note: Approximately Dry Fill Capacity Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 2444 Fluid - A/T: Fluid Type Specifications See TSB 06-14-4 Transmission Fluid Type 4R100 .................................................................................................................................................. .................................................................. MERCON 4R70W ............................................................. ................................................................................................................................................. MERCON V MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 2445 Fluid - A/T: Service and Repair Removal 1. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If this concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Remove the drain plug to allow the fluid to drain. 4. CAUTION: When replacing the transmission fluid and filter and seal assembly; the torque converter should be drained. Transmission cooler, cooler lines, and cooler bypass valve must be thoroughly flushed to remove any contamination. Note: Do not discard the fluid pan gasket unless damaged. This is a reusable gasket. Remove the transmission fluid pan and gasket. 1 Loosen, but do not remove the bolts. 2 Remove the front and side bolts. 3 Lower the front of the t1uid pan and allow the fluid to drain. 4 Remove the remaking fluid pan bolts and the fluid pan. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 2446 5. Note: After removal, discard the filter and seal assembly. Remove the filter and seal assembly by carefully pulling and rotating the filler as necessary. 6. CAUTION: Be careful not to scratch or damage the aluminum bore. The new seal may leak and damage to the case will result. If the seal remains in the pump bore, remove it carefully with a small screwdriver so as not to scratch or damage the aluminum bore. 7. Remove the torque converter drain plug cover. 8. Remove the torque converter drain plug. 9. Note: If equipped with a radiator in-tank transmission fluid cooler, or an auxiliary cooler, the coolers will need to be flushed. Thoroughly flush the cooler lines, fluid coolers, and the cooler bypass valve. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 2447 1. After the torque converter has drained, install the drain plug. 2. Install the torque converter drain plug cover. 3. Note: Prior to installation, lightly lubricate the seal with clean MERCON Multipurpose (ATF) Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Press a new fluid filtered seal assembly into the pump bore until seated. 4. CAUTION: Mixing (A) 4x2-style and (B) 4x4-style transmission fluid filters and transmission pan assembly components can cause transmission damage. Install filter assembly and transmission pan. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 2448 5. Note: The transmission pan gasket is reusable unless damaged. Note: Apply a light coat of petroleum jelly to hold the gasket to the fluid pan. Position the (A) gasket onto the cleaned fluid pan. Make sure the (B) magnet is positioned over the dimple in the fluid pan. 6. Install the fluid pan. 1 Position the fluid pan. 2 Install the bolts. 7. Lower the vehicle. 8. Reconnect the battery ground cable. 9. CAUTION: Use only MERCON Multipurpose (ATF) Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON. The use of any other fluids can result in the transmission failing to operate in a normal manner or failure. Refill the transmission. Add 6.2 liters (6.5 quarts) of Motorcraft MERCON Multipurpose (ATF) Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON, to the transmission through the fluid filler tube. - Start the engine. Move the transmission range selector lever through all the gear ranges and allow to engage before moving to the next gear. - Check and adjust the transmission fluid, in 0.24 liter (0.5 pint) increments, to the proper level (cross-hatched area of the fluid level Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front Differential Oil Capacity Refill ..................................................................................................................................................... ..................................................................... 1.8-2.0L Rear Differential Oil Capacity Refill ..................................................................................................................................................... ..................................................................... 2.9-3.1L Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 2453 Fluid - Differential: Fluid Type Specifications Front Differential Fluid Type Motorcraft SAE 75W-90 Premium 4x4 Front Axle Lubricant XY-75W90-TQL Specification ............... .............................................................................................................................................................. ................. WSP-M2C201-A Rear Differential Fluid Type Type .................................................................................................................................................. SAE 75W140 High Performance Rear Axle Lubricant Additive Friction Modifier ................................ .......................................................................................................................................... C8AZ-19B546-A Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Capacity ....................................................................................................................... .................................................................... 2.0 Quarts Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 2458 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid Type ..................................................................................................................................................... ............................................................. Mercon ATF Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2463 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2464 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2465 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications 4.6L and 5.4L Engine Automatic Transmission ...................................................................................................................... ................................................... 6.675 quarts ± 0.125 Manual Transmission .......................................................................................................................... ................................................... 6.425 quarts ± 0.125 5.4L (4V) Engine .................................................................................................................................. .......................................................... 6.62L (7.0 qt)* * With filter. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2468 Engine Oil: Fluid Type Specifications Engine Oil ............................................................................................................................................ ............................................................... SAE 5W-20 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 2473 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 2474 Power Steering Fluid: Specifications / / Power Steering Fluid Type MERCON(R) ATF Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Service and Repair > Fill Power Steering Fluid: Service and Repair Fill 1. WARNING: Do not mix oil types. Any mixture or any unapproved oil could lead to seal deterioration and leaks. A leak could ultimately cause loss of fluid, which could result in a loss of power steering assist. Fill the power steering reservoir to appropriate level. Use Motorcraft MERCON Multi-Purpose Transmission Fluid, XT-2-QDX or equivalent meeting Ford specification MERCON. 2. Remove the ignition coil fuse number 30 in the fuse junction panel to disable the engine from starting. 3. Raise the front wheels off the floor. 4. CAUTION: Do not operate the starter motor for more than 10 seconds at a time. Damage to the starter motor could result. Turn the steering wheel from stop to stop while cranking the engine. 5. Lower the vehicle. 6. WARNING: Do not mix oil types. Any mixture or any unapproved oil could lead to seal deterioration and leaks. A leak could ultimately cause loss of fluid, which could result in a loss of power steering assist. CAUTION: Do not overfill the power steering fluid reservoir. Fill the power steering fluid reservoir to the appropriate level. Use Motorcraft MERCON Multi-Purpose Transmission Fluid, XT-2-QDX or equivalent meeting Ford specification MERCON. 7. Install the ignition coil fuse number 30 in the fuse junction panel fuse box. 8. Note: If the power steering is noisy and accompanied by evidence of aerated fluid, it will be necessary to purge the power steering system. Clear the Diagnostic Trouble Codes (DTCs). Run vehicle and check the system for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Service and Repair > Fill > Page 2477 Power Steering Fluid: Service and Repair System Flushing WARNING: Do not mix oil types. Any mixture or any unapproved oil could lead to seal deterioration and leaks. A leak could ultimately cause loss of fluid, which could result in a loss of power steering assist. 1. Remove the ignition coil fuse number 30 in the fuse junction panel to disable the engine from starting. 2. Disconnect the power steering return hose. 1. Compress and move the hose clamp. 2. Disconnect the power steering return hose and plug the fitting to the reservoir. 3. Attach an extension hose between the power steering return hose and an empty container. 4. WARNING: Do not mix oil types. Any mixture or any unapproved oil could lead to seal deterioration and leaks. A leak could ultimately cause loss of fluid, which could result in a loss of power steering assist. Fill the power steering fluid reservoir to the appropriate level. Use Motorcraft MERCON Multi-Purpose Transmission Fluid, XT-2-QDX or equivalent MERCON approved fluid. 5. Raise the front wheels off the ground. 6. CAUTION: Do not operate the starter motor for more than 10 seconds at a time. Damage to the starter motor could result. Turn the steering wheel from stop to stop while cranking the engine until the fluid exiting the extension hose is clean. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Service and Repair > Fill > Page 2478 7. Disconnect the extension hose from the power steering return hose and attach the power steering return hose to the power steering fluid reservoir. 8. WARNING: Do not mix oil types. Any mixture or any unapproved oil could lead to seal deterioration and leaks. A leak could ultimately cause loss of fluid, which could result in a loss of power steering assist. CAUTION: Do not overfill the power steering fluid reservoir. Fill the power steering fluid reservoir to the appropriate level. Use Motorcraft MERCON Multi-Purpose Transmission Fluid, XT-2-QDX or equivalent MERCON approved fluid. 9. Install the ignition coil fuse. 10. CAUTION: Do not hold the steering wheel against the stops for more than five seconds; damage to the power steering pump may occur. Start the engine and turn the steering wheel from stop to stop. 11. Note: If power steering is noisy and accompanied by aerated fluid, it will be necessary to purge the power steering system. Check the power steering fluid level. 12. Clear Diagnostic Trouble Codes (DTCs). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 2483 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 2484 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 2485 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 2486 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Capacity without auxiliary Capacity with auxiliary R-134a Refrigerant YN-19 37 oz (US) 62 oz (US) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 2489 Refrigerant: Fluid Type Specifications R-134a Refrigerant Ford Part Number................................................................................................................................. ...................................................Motorcraft YN-19 Ford Specification................................................................................................................................. ....................................................WSH-M17B19-A Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2490 Refrigerant: Service Precautions The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level Vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Additional Information Sources For more complete and detailed explanations of the above policies, please refer to: http://www.epa.gov/ozone/ Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 732-4600 Fax: (817) 732-9610 http://www.imaca.org/ Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2491 Fax: 215-541-4635 http://www.macsw.org/ Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2492 Refrigerant: Service and Repair SPECIAL SERVICE TOOL(S) CAUTION: The A/C refrigerant of all vehicles must be identified and analyzed prior to refrigerant charging. Failure to do so can contaminate the shop bulk refrigerant and other vehicles. See: Heating and Air Conditioning/Service and Repair/Identifying Refrigerants 1. Connect the R-134a A/C Refrigerant Center to the low and high-pressure service gauge port valves. 2. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer. 3. Once the service center has recovered the vehicle A/C system refrigerant, close the service center inlet valve (if so equipped). Then switch off the power supply. 4. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system vacuum level as shown on the gauge. If the pressure does not rise, disconnect the recovery station hose(s). 5. If the system pressure rises, repeat steps 2 through 5 until the vacuum level remains stable for two minutes. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Fluid Type Specifications Refrigerant Oil: Fluid Type Specifications PAG Refrigerant Compressor Oil (R-134a Systems) Ford Part Number................................................................................................................................. ................F7AZ-19589-DA (Motorcraft YN-12-C) Ford Specification................................................................................................................................. ...................................................WSH-M1C231-B Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2497 Refrigerant Oil: Service and Repair CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. ^ If the amount of oil drained from the old A/C compressor is between 85 - 142 ml (3 - 5 ounces), pour the same amount plus 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. ^ If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. ^ If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. NOTE: Service A/C compressors are shipped without compressor oil. 2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier cylinder and drain the oil into a calibrated container. 1 Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2498 4. For the A/C condenser core, add 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube when performing each of the following repairs: ^ replacement of the A/C evaporator core orifice ^ replacement of the A/C compressor pressure relief valve ^ replacement of a refrigerant line ^ repair of an O-ring seal leak ^ repair of a charge port leak 6. Installation of new components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Front disc brake caliper bleeder screw 9 - 13 ft.lb Front master cylinder brake tube 17 - 20 ft.lb Rear disc brake caliper bleeder screw 12 - 18 ft.lb Rear master cylinder brake tube 11 - 14 ft.lb Wheel cylinder bleeder screw 63 - 80 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed Brake Bleeding: Service and Repair Brake Master Cylinder - Bench Bleed WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with specified brake fluid. ^ Use High Performance DOT 3 Brake Fluid C6AZ-1 9542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir. 3. Slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles. 4. Remove the short brake tubes. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2504 Brake Bleeding: Service and Repair Brake Master Cylinder - In-Vehicle Bleed Special Tools WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Note: When a new brake master cylinder has been installed or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. Disconnect the brake master cylinder outlet tubes. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2505 2. Install short brake tubes with ends submerged in the brake master cylinder reservoir and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes without air bubbles. 4. Remove the short brake tubes and install the brake outlet tubes. 5. Bleed each brake tube at the brake master cylinder as follows: 1. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 2. Loosen the rear most brake tube fittings until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the brake tube fitting. 3. Repeat this operation until clear, bubble-free fluid comes out. 4. Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. 6. While the assistant maintains pressure on the brake pedal, tighten the brake tubes. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2506 Brake Bleeding: Service and Repair Brake System Gravity Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. Note: When a new brake master cylinder has been installed or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. 1. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Bleed the rear disc brake calipers. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. 2. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. ^ Repeat for LH rear disc brake caliper. 3. Tighten the rear disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2507 4. Bleed the front disc brake calipers. 1. Place a box end wrench on the RH front disc brake caliper bleeder screw. 2. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. ^ Repeat for LH front disc brake caliper. 5. Tighten the front disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2508 Brake Bleeding: Service and Repair Brake System Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. 5. Repeat Steps 1, 2, 3, and 4 for the LH rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2509 6. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 7. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 8. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 9. Tighten the RH front disc brake caliper bleeder screw. 10. Repeat Steps 6, 7, 8, and 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2510 Brake Bleeding: Service and Repair Brake Master Cylinder - Bench Bleed WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with specified brake fluid. ^ Use High Performance DOT 3 Brake Fluid C6AZ-1 9542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir. 3. Slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles. 4. Remove the short brake tubes. Brake Master Cylinder - In-Vehicle Bleed Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2511 Special Tools WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Note: When a new brake master cylinder has been installed or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. Disconnect the brake master cylinder outlet tubes. 2. Install short brake tubes with ends submerged in the brake master cylinder reservoir and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes without air bubbles. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2512 4. Remove the short brake tubes and install the brake outlet tubes. 5. Bleed each brake tube at the brake master cylinder as follows: 1. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 2. Loosen the rear most brake tube fittings until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the brake tube fitting. 3. Repeat this operation until clear, bubble-free fluid comes out. 4. Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. 6. While the assistant maintains pressure on the brake pedal, tighten the brake tubes. Brake System Gravity Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. Note: When a new brake master cylinder has been installed or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. 1. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Bleed the rear disc brake calipers. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. 2. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. ^ Repeat for LH rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2513 3. Tighten the rear disc brake caliper bleeder screws. 4. Bleed the front disc brake calipers. 1. Place a box end wrench on the RH front disc brake caliper bleeder screw. 2. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. ^ Repeat for LH front disc brake caliper. 5. Tighten the front disc brake caliper bleeder screws. Brake System Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2514 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. 5. Repeat Steps 1, 2, 3, and 4 for the LH rear disc brake caliper. 6. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 7. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 8. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2515 9. Tighten the RH front disc brake caliper bleeder screw. 10. Repeat Steps 6, 7, 8, and 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Brake System Pressure Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. Note: Bleed the longest line first. Be sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. Note: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2516 3. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the rear disc brake caliper bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten rear disc brake caliper bleeder screw and remove the rubber hose. 6. Continue bleeding the rest of the system, going in order from the LH rear disc brake caliper to the RH front disc brake caliper (213121) ending with the LH front disc brake caliper. 7. Close the bleeder tank valve and remove the tank hose from the adapter and remove the adapter. 8. Fill the brake master cylinder reservoir and install the brake master cylinder filler cap. Four Wheel Antilock Brake System Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. Note: This procedure must be performed if the 4 wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been installed new. Note: One conventional pressure bleed cycle consists of advancing the brake pedal to its depressed position, opening the disc brake caliper bleeder screw, allowing fluid to be released into the waste container, closing the disc brake caliper bleeder screw and releasing the brake pedal. Note: Performing the NGS program routine drives entrapped air from the otherwise inaccessible lower section of the 4WABS valve into the upper sections (accessible by bleeding the brakes). Subsequent bleedings remove the air from the system. Note: Add recommended brake fluid as necessary throughout the procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2517 1. Connect a clear waste line to the RH rear disc brake caliper bleeder screw and the other end in a container partially filled with recommended brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. 5. Repeat Steps 1, 2, 3, and 4 for the LH rear disc brake caliper bleeder screw, RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw. 6. Note: Go to the help menu in the scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 2518 Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the dash and follow the scan tool instructions. 7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal feels spongy, repeat the scan tool service bleed procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Page 2519 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Supplemental Restraint System ( SRS ) Depowering and Repowering Depowering Procedure Warning: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Warning: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F22 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. Warning: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 6. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 1. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse F22 (10A) to the CJB and close the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 4. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2524 The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Deactivation and Reactivation Supplemental Restraint System ( SRS ) Deactivation and Reactivation Special Tool(s) Deactivation Warning: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Warning: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. Warning: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Warning: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. Warning: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All Vehicles 1. Move and tilt the front seats to their highest and most forward position. 2. Turn all vehicle accessories OFF. 3. Turn the ignition switch to OFF. 4. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F22 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 5. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 6. Turn the ignition OFF. Warning: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2525 The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 7. Disconnect the battery ground cable (14301) and wait at least one minute. 8. Remove the two steering wheel back cover plugs. 9. Remove the two driver air bag module retaining bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2526 10. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Disconnect the horn switch electrical connector. 3. Remove the driver air bag module. 11. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2527 12. Remove the instrument panel relay cover. 13. Disconnect the passenger air bag module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2528 14. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicle without side airbags Caution: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. 15. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM) If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with side airbags 16. Disconnect the passenger seat side air bag electrical connector. 1. Slide and disengage the passenger seat side air bag electrical connector locking clip. 2. Push in to release the tab and disconnect the passenger seat side air bag electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2529 17. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 18. Disconnect the driver seat side air bag electrical connector. 1. Slide and disengage the driver seat side air bag electrical connector locking clip. 2. Push in to release the tab and disconnect the driver seat side air bag electrical connector. 19. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All Vehicles 20. Install the RCM fuse F22 (10A) to the CJB. 21. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2530 Reactivation All Vehicles 1. Remove the RCM fuse F22 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles with side airbags 3. Remove the restraint system diagnostic tool from the driver side seat air bag floor electrical connector. 4. Connect the driver seat side air bag electrical connector. 1. Connect the driver seat side air bag electrical connector. 2. Slide and engage the driver seat side air bag electrical connector locking clip. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2531 5. Remove the restraint system diagnostic tool from the passenger side seat air bag floor electrical connector. 6. Connect the passenger side seat air bag electrical connector. 1. Connect the passenger side seat air bag electrical connector. 2. Slide and engage the passenger side seat air bag electrical connector locking clip. All Vehicles 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2532 8. Connect the passenger air bag module electrical connector. 9. Install the instrument panel relay cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2533 10. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Connect and position the driver air bag module. 1. Connect the horn switch electrical connector. 2. Connect the driver air bag module electrical connector. 3. Position the driver air bag module to the steering wheel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2534 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 14. 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. 15. Turn the ignition switch from OFF to ON. 16. Install the RCM fuse F22 (10A) to the CJB and close the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 17. Connect the battery ground cable. 18. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 2535 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Is the air bag system connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Are the side air bag electrical connectors beneath the front seats connected? 4. Is the Restraints Control Module (RCM) connected? 5. Is the vehicle battery connected? Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box Fuse: Locations Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box > Page 2541 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box > Page 2542 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box > Page 2543 Fuse: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box > Page 2544 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box > Page 2545 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2548 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2549 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2550 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2551 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2552 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2553 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2554 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2555 Fuse: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2556 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2557 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2558 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2559 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2560 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 2561 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box Fuse: Application and ID Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box > Page 2564 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box > Page 2565 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box > Page 2566 Fuse: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box > Page 2567 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box > Page 2568 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box Fuse Block: Locations Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box > Page 2573 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box > Page 2574 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box > Page 2575 Fuse Block: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box > Page 2576 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box > Page 2577 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2580 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2581 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2582 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2583 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2584 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2585 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2586 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2587 Fuse Block: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2588 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2589 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2590 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2591 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2592 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2593 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2594 Fuse Block: Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2595 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Battery Junction Box Fuse Block: Application and ID Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 2598 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 2599 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 2600 Fuse Block: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 2601 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 2602 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box Relay Box: Locations Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box > Page 2607 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box > Page 2608 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box > Page 2609 Relay Box: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box > Page 2610 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box > Page 2611 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 2614 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 2615 Relay Box: Diagrams Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 2616 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 2617 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 2618 Relay Box: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 2619 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 2620 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 2621 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box Relay Box: Application and ID Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 2624 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 2625 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 2626 Relay Box: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 2627 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 2628 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation SERVICE ENGINE SOON Your vehicle is equipped with a computer that monitors the engine's emission control system. This is commonly known as the On Board Diagnostic System (OBD II). This OBD II system protects the environment by ensuring that your vehicle continues to meet government emission standards. The OBD II system also assists the service technician in properly servicing your vehicle. The SERVICE ENGINE SOON indicator light illuminates when the ignition is first turned to the ON position to check the bulb. If it comes on after the engine is started, on of the engine's emission control systems may be malfunctioning. The light may illuminate without a driveability concern being noted. The vehicle will ususally be drivable and will not require towing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation > Page 2633 Maintenance Required Lamp/Indicator: Service and Repair Solid SERVICE ENGINE SOON light This means that the On Board Diagnostic System (OBD II) has detected a malfunction. Temporary malfunctions may cause your SERVICE ENGINE SOON light to illuminate. Examples are: 1. The vehicle has run out of fuel. (The engine may misfire or run poorly.) 2. Poor fuel quality or water in the fuel. 3. The fuel cap may not have been properly installed and securely tightened. The temporary malfunctions can be corrected by filling the fuel tank with good quality fuel and/or properly installing and securely tightening the gas cap. After three driving cycles with out these or any other temporary malfunctions present, the SERVICE ENGINE SOON light should turn off. (A driving cycle consists of a cold engine start-up followed by mixed city/highway driving.) No additional vehicle service is required. Blinking SERVICE ENGINE SOON light Engine misfire is occurring which could cause damage to your catalytic converter. You should drive in a moderate fashion (avoid heavy acceleration and deceleration) and have your vehicle serviced at the first available opportunity. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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) Schematic CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) alerts the driver that the Powertrain Control Module (PCM) has detected an On Board Diagnostic (OBD) II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. ^ The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol. ^ Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. ^ The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. ^ If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. ^ If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. ^ To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. ^ For any MIL concern Symptom Charts. ^ If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. ^ If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair The manufacturer does NOT show that this vehicle is equipped with an oil change reminder lamp. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK CAUTION: Never use a halfshaft as a lifting point. Jacking Points - Front, 4x4 The jacking point is a raised boss located on the front suspension lower arm. Jacking Points - Front, 4x2 The jacking point is a flat portion on the frame indicated by an arrow cutout in the frame, located behind the front tire and wheel assembly. Jacking Points - Rear Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 2644 CAUTION: Never use the differential housing as a lifting point. The rear jacking points are located on the rear axle. LIFTING WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Lifting Points - Twin Post Hoist Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. Lifting Points - Drive On Hoist The vehicle is supported by tires and suspension components. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair Spare Tire: Service and Repair Removal 1. Lower the spare tire. 1. Insert the drive end of the jack handle through the opening left of the license plate. 2. Turn the jack handle until slack is present in the cable. 2. Remove the spare tire. 1. Slide the retainer through the center of the spare tire assembly. 2. Remove the spare tire assembly. 3. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 4. Remove the spare tire carrier. 1. Remove the bolts. 2. Turn the spare tire carrier to disengage the spare tire carrier from the tabs and remove the spare tire carrier. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair > Page 2649 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Correct Lug Nut Torque Specifications Wheels: Technical Service Bulletins Wheels - Correct Lug Nut Torque Specifications Article No. 03-22-4 11/10/03 WHEEL - CORRECT LUG NUT TORQUE SPECIFICATIONS - INCREASED WHEEL NUT AND STUD SIZE - SERVICE TIP FORD: 2000-2004 EXPEDITION, F-150 LINCOLN: 2000-2004 NAVIGATOR This article supersedes TSB 99-26-3 to update the vehicle model years. ISSUE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Correct Lug Nut Torque Specifications > Page 2654 All 2000-2004 F-150 (excluding F-150 equipped with 7-stud wheels and the 7700 payload group) and Expedition/Navigator built on or after November 27, 1999 will have revised wheel stud and wheel nut diameters. The wheel studs/nuts wilt have increased thread diameter from 12 mm to 14 mm. This change will include revised wheels, center wheel ornaments, hubs, brake rotors, wheel nuts, and lug wrench (two piece design and 13 cm (5") longer). ACTION The 14 mm wheel nut will require a 21 mm socket, instead of the 19 mm socket used on the 12 mm wheel nuts. The torque specification for the l4mm wheel nuts is 200 N.m (150 lb-ft). A TORQUE WRENCH MUST BE USED TO INSURE PROPER TORQUE IS ACHIEVED. The torque specification for the 12 mm wheel nut will remain at 133 N.m (100 lb-ft). NOTE THE 14 mm PARTS ARE NOT INTERCHANGEABLE WITH THE PREVIOUS 12 mm PARTS. CAUTION WHENEVER WHEEL/TIRE REMOVAL AND INSTALLATION IS REQUIRED, FOLLOW THE PROCEDURES AS OUTLINED IN THE APPROPRIATE WORKSHOP MANUAL (SECTION 204). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Correct Lug Nut Torque Specifications > Page 2655 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-26-3 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Correct Lug Nut Torque Specifications > Page 2656 Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Correct Lug Nut Torque Specifications > Page 2657 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2658 Wheels: Specifications Maximum Wheel Rim Runout (Radial Or Lateral) .............................................................................................................................. 1.12 mm (0.044 inch) Maximum Balance Weight (Total Of Inner And Outer Wheel Flanges) ........................................................................................................... 170 g (6 oz.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2659 Wheels: Service Precautions WARNING: Never run the engine with one wheel off the ground, for example, when changing a tire. The wheel resting on the ground could cause the vehicle to move. - The tire and wheel must always be correctly matched. It is very important to determine the size of each component before any assembly operations commence. Do not mount a 16-inch tire on a 16.5-inch wheel. Failure to adhere to these instructions can result in an explosive separation and cause serious bodily injury or death. Do not mount a 16.5-inch tire on a 16-inch wheel. The tire can come off without warning. - Aftermarket aerosol tire sealants are extremely flammable. Always question the customer to make sure these products have not been used. - Use only wheels and wheel nuts that have been designed for current model year ford trucks. Aftermarket wheels or wheel nuts may not fit or function correctly, and can cause personal injury or damage the vehicle. - Always wear safety goggles or a face shield when performing any work with tire and wheel assemblies. - Retighten the wheel nuts at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened. - Failure to retighten wheel nuts at the mileage specified can allow wheels to come off while the vehicle is in motion, possibly causing loss of vehicle control and collision. CAUTION: Do not clean aluminum wheels with steel wool, abrasive-type cleaners or strong detergents. Use Custom Bright Metal Cleaner .8A-19522-A or equivalent meeting Ford specification ESR-M5B194-B. - Reduce the air pressure as much as possible by pushing the valve core plunger in prior to removing the valve core. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2660 Wheels: Description and Operation WARNING: Do not mix different types of tires, such as radial, bias, or bias-belted, on the same vehicle except in emergencies (temporary spare usage). Vehicle handling can be seriously affected and can result in loss of control. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures. Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increase tire wear. Replacement tires should follow the recommended: tire sizes. - speed rating. - load range. - radial construction type. Use of any other tire size or type may seriously affect: ride. - handling. - speedometer/odometer calibration. - vehicle ground clearance. - tire clearance between the body and chassis. - Wheel bearing life. - brake cooling. New wheels need to be installed when: bent. - dented. - heavily rusted. - leaking. - they have elongated wheel hub bolt holes. - they have excessive lateral or radial runout. The Expedition uses a two-piece wheel nut, containing the nut and a washer. Wheel and tire assemblies are attached by five noncentering wheel nuts. When balancing wheels and tires, use T-type balancing weights. The spare tire is mounted under the frame. The valve stem should. be on the top side of the tire to reduce the possibility of accidental valve stem air leakage. To equalize tire wear, rotate the tires periodically. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire Wheels: Service and Repair Wheel and Tire Removal 1. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and wheel bearings. Note: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the wheel nuts. 1. Remove the center cap. 2. With the weight of the vehicle on the wheels, loosen the wheel nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 1. Remove the wheel nuts. 2. Remove the wheel and tire assembly using a side-to-side rocking motion. Installation All vehicles 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. WARNING: Retighten at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened. - Failure to retighten wheel nuts at the mileage specified could allow wheels to come off while the vehicle is in motion, possibly causing loss of vehicle control and collision. Clean the wheel hub mounting surface. 2. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the tire and wheel assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire > Page 2663 - Position the tire and wheel assembly. - Install the wheel nuts, hand-tight, then lower the vehicle. Vehicles with 12 mm wheel bolts 3. CAUTION: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the wheel nuts in sequence. Vehicles with 14 mm wheel bolts 4. CAUTION: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the wheel nuts in sequence. All vehicles 5. Install the center cap. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire > Page 2664 Wheels: Service and Repair Wheel Leaks CAUTION: Do not attempt to repair aluminum wheels that leak air. 1. If repairs are made to the wheel, the structural integrity of the wheel can be lost. Install a new aluminum wheel if it leaks air. 2. Install new or repair any wheel that leaks air. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Page 2665 Special Tools Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricate the new rear wheel bearing. - Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 2669 Wheel Bearing: Testing and Inspection Wheel Bearing Check 1. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Spin the tire by hand to check the wheel bearings for roughness. NOTE: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 2670 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate service procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Ford Wheel Bearing: Service and Repair Ford Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. 3. Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing, and the wheel bearing oil seal. Installation 1. Lubricate the new rear wheel bearing. - Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Ford > Page 2673 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Ford > Page 2674 Wheel Bearing: Service and Repair Front Removal Note: The wheel bearing and hub are installed as an assembly. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and wheel bearings. Remove the wheel and tire assembly. 3. Remove the brake disc. 4. Remove the front wheel hub nut. 1. Remove and discard the cotter pin. 2. Remove the retainer. 3. Remove the nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Ford > Page 2675 5. Remove the brake disc shield. 1. Remove the bolts. 2. Remove the brake disc shield. 6. Remove the front brake anti-lock sensor. 1. Remove the bolt. 2. Remove the front brake anti-lock sensor. 7. CAUTION: Do not over-extend the CV joint and boots when removing the hub and bearing assembly. Note: The CV joint is a slip fit into the wheel hub and bearing. A puller will not normally be required. Remove the wheel hub. 1. Remove the bolts. 2. Push the CV joint inboard. Remove the wheel hub. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Ford > Page 2676 8. Remove the seal. Installation 1. Install the seal using the Knuckle Seal Replacer, the Threaded Drawbar and Bearing Cup Replacer. 2. Install the wheel hub. 1. Position the wheel hub on the front wheel driveshaft and joint and into the front wheel knuckle. 2. Install the wheel hub bolts. 3. Install the front brake anti-lock sensor. 1. Install the front brake anti-lock sensor into the wheel hub. 2. Install the front brake anti-lock sensor bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Ford > Page 2677 4. Install the brake disc shield and front axle hub nut. 1. Position the brake disc shield. 2. Install the bolts. 3. Install the front axle hub nut. 4. Install the retainer. 5. Install a new cotter pin. 5. Install the brake disc. 6. WARNING: When the wheel is installed, always remove any corrosion, dirt or foreign material that may be present on the mounting surfaces of the wheels or the surfaces of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can cause the wheel nut to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. WARNING: ^ Retighten at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened. ^ Failure to retighten wheel nuts at the mileage specified could allow wheels to come off while the vehicle is in motion, possibly causing loss of vehicle control and collision. Install the tire and wheel assembly. 7. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Hub Nut .............................................................................................................................. ................................. 255-345 Nm (188-254 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Wheels - Correct Lug Nut Torque Specifications Wheel Fastener: Technical Service Bulletins Wheels - Correct Lug Nut Torque Specifications Article No. 03-22-4 11/10/03 WHEEL - CORRECT LUG NUT TORQUE SPECIFICATIONS - INCREASED WHEEL NUT AND STUD SIZE - SERVICE TIP FORD: 2000-2004 EXPEDITION, F-150 LINCOLN: 2000-2004 NAVIGATOR This article supersedes TSB 99-26-3 to update the vehicle model years. ISSUE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Wheels - Correct Lug Nut Torque Specifications > Page 2686 All 2000-2004 F-150 (excluding F-150 equipped with 7-stud wheels and the 7700 payload group) and Expedition/Navigator built on or after November 27, 1999 will have revised wheel stud and wheel nut diameters. The wheel studs/nuts wilt have increased thread diameter from 12 mm to 14 mm. This change will include revised wheels, center wheel ornaments, hubs, brake rotors, wheel nuts, and lug wrench (two piece design and 13 cm (5") longer). ACTION The 14 mm wheel nut will require a 21 mm socket, instead of the 19 mm socket used on the 12 mm wheel nuts. The torque specification for the l4mm wheel nuts is 200 N.m (150 lb-ft). A TORQUE WRENCH MUST BE USED TO INSURE PROPER TORQUE IS ACHIEVED. The torque specification for the 12 mm wheel nut will remain at 133 N.m (100 lb-ft). NOTE THE 14 mm PARTS ARE NOT INTERCHANGEABLE WITH THE PREVIOUS 12 mm PARTS. CAUTION WHENEVER WHEEL/TIRE REMOVAL AND INSTALLATION IS REQUIRED, FOLLOW THE PROCEDURES AS OUTLINED IN THE APPROPRIATE WORKSHOP MANUAL (SECTION 204). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Wheels - Correct Lug Nut Torque Specifications > Page 2687 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-26-3 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 2688 Wheel Fastener: Specifications Vehicles with 12 mm wheel bolts Tighten the wheel nuts in sequence to 135 Nm (100 ft. lbs.). Vehicles with 14 mm wheel bolts Tighten the wheel nuts in sequence to 204 Nm (150 ft. lbs.). CAUTION: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 2689 Wheel Fastener: Service and Repair Removal 1. Remove the wheel hub. 2. CAUTION: Do not press on the bearing when removing or installing wheel studs. Remove the damaged wheel studs. Installation 1. CAUTION: Do not press on the bearing when removing or installing wheel studs. Install the new wheel studs. 2. Install the wheel hub. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK CAUTION: Never use a halfshaft as a lifting point. Jacking Points - Front, 4x4 The jacking point is a raised boss located on the front suspension lower arm. Jacking Points - Front, 4x2 The jacking point is a flat portion on the frame indicated by an arrow cutout in the frame, located behind the front tire and wheel assembly. Jacking Points - Rear Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 2693 CAUTION: Never use the differential housing as a lifting point. The rear jacking points are located on the rear axle. LIFTING WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Lifting Points - Twin Post Hoist Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. Lifting Points - Drive On Hoist The vehicle is supported by tires and suspension components. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 within 75 percent of the highest reading. For additional information, refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2699 Compression Check: Testing and Inspection General Remarks Note: Removing fuses and disconnecting electrical components causes the Powertrain Control Module (PCM) to log an error message. After the measurements have been carried out this error message should be cleared from memory by connecting to PDU. Note: Only check the compression pressure with the valves set to the prescribed clearance (if this can be adjusted). The compression pressure should be checked with the engine at operating temperature. Check The Compression Pressure WARNING: On manual transmissions shift the transmission into neutral. On automatic transmission vehicles, select "P". Failure to follow these instructions may result in personal injury. 1. Remove the fuel pump relay. 2. Start the engine-the engine will start, run for a few seconds then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter switch in the starting circuit. With the ignition switch OFF, using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 6. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 7. Install the components in reverse order, observing the specified tightening torques. 8. Reset the PCM fault memory. Interpretation of the Results The indicated compression pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading. CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent damage to the catalytic converter. If the measurement on one or more cylinders is much lower than the specified value, spray some engine oil into the combustion chamber and repeat the compression measurement. If the reading greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other arc both too low then it is very likely that the cylinder head gasket between them is burnt through. This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 71-106 in.lb Sequence - Romeo Engine --Sequence - Windsor Engine --- Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications > Page 2704 Camshaft Bearing: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft sprocket bolts refer to the procedure in this section Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Lobe Lift Exhaust 7.49744 mm Intake 7.11038 mm Lobe Lift-Allowable Lift Loss 0 mm Valve Lift @ Zero Lash Intake 13.01 mm Exhaust 13.75 mm Camshaft End Play 0.027 - 0.190 mm End Play Service Limit 0.025 - 0.190 mm Journal to Bearing Clearance 0.076 - 0.025 mm Journal Diameters 26.962 - 29.936 mm Camshaft Runout 27.012 - 26.987 mm Full Indicator Measurement on all journals when supported on front and rear journals. (4 places) 0.03 mm Camshaft bearing cap bolts 71-106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2711 Camshaft: Service and Repair Removal 1. Remove the camshaft roller followers. 2. CAUTION: At no time, when the timing chains are removed and the cylinder heads (6049) are installed may the crankshaft (6303) or camshaft (6250) be rotated. Severe piston and valve damage will occur. Remove the timing chains (6268).See: Timing Components/Service and Repair 3. Note: Romeo engine shown; Windsor engine similar. On engines with bolt on sprockets, remove the camshaft sprocket 1 Remove the bolt. 2 Remove the camshaft sprocket. 4. Remove the camshaft holding tool. 5. Note: The Windsor engine is shown; the Romeo engine is similar. Remove the thirteen camshaft bearing cap bolts. 6. Note: The Windsor cylinder head is shown; the Romeo cylinder head is similar. Note: The camshaft bearing caps are positional. Mark the caps for installation in their original locations. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2712 Remove the camshaft bearing caps. 7. Remove the camshaft from the cylinder head. Installation All Vehicles 1. Lubricate the camshaft journals. - Use Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2053-G. 2. Install the camshaft onto the cylinder head. 3. Lubricate the camshaft bearing caps. - Use Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2713 Windsor Engine 4. On Windsor engines, install the camshaft bearing caps in their original locations. - Position the camshaft bearing caps. - Loosely install the bolts. Romeo Engine 5. On Romeo engines, install the camshaft bearing caps in their original locations. 1 Position the camshaft bearing caps. 2 Loosely install the bolts. Windsor Engine Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2714 6. On Windsor engines, tighten the bolts in the sequence shown. Romeo Engine 7. On Romeo engines, tighten the bolts in the sequence shown. 8. Install camshaft holding tool. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2715 9. On engines equipped with bolt on sprockets, install the camshaft sprocket (2). 1 Install the bolt (1). 2 Tighten the bolt. - M10 bolt: Tighten in two stages. - Stage 1: Tighten to 40 Nm (30 ft. lbs.). - Stage 2: Tighten an additional 90 degrees. - M12 bolt: Tighten to 120 Nm (90 ft. lbs.). All Vehicles 10. Install the timing chains. 11. Install the roller followers. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair Lifter / Lash Adjuster: Service and Repair Removal 1. Remove the camshaft roller followers. 2. Note: The valve tappets are positional. Mark each valve tappet for installation in it's original location. Remove the valve tappets. Installation 1. Install the valve tappets in their original locations. 2. Install the camshaft roller followers. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2727 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2728 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: Customer Interest Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2734 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2735 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2736 Rocker Arm Assembly: Service and Repair Special Tools Removal 1. Remove the valve cover. 2. Position the piston of the cylinder being repaired at the bottom of the stroke. 3. Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal damage. 4. Note: The roller followers are positional. Mark the followers for installation in their original locations. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2737 Use the Valve Spring Compressor to compress the valve springs and remove the cam roller followers. Installation 1. Use the (A) Valve Spring Compressor to compress the (B) valve spring and install the (C) camshaft roller followers in their original locations. 2. Remove the Valve Spring Spacer. 3. Install the valve covers. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair Connecting Rod Bearing: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt Connecting Rod: Specifications Connecting Rod Bolt CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Use the Connecting Rod Guide Tool and the Piston Ring Compressor to install the connecting rod with upper connecting rod bearing in place. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Guide Tool. CAUTION: The rod cap installation must keep the same orientation as marked during disassembly. Note: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly. Position the lower bearing and connecting rod, and install the new bolts loosely. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt > Page 2746 Tighten the bolts in two stages, using the sequence shown. Stage 1: Tighten to 40 - 45 Nm (30 - 33 ft. lbs.). - Stage 2: Tighten an additional 90 - 120 degrees. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt > Page 2747 Connecting Rod: Specifications Big End Journal Inside Diameter with Assembled Liners 53.049 - 53.027 mm Rod Bearing to Journal Clearance 0.064 - 0.026 mm Rod Length (Centerline Bore-to-Bore) 196.1 mm Bore-to-Bore Max. Twist +/- 0.05 mm Bore-to-Bore Max. Bend +/- 0.038 mm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 2748 Connecting Rod: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications Cylinder block drain plug 12 - 18 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Crankshaft Journal to Main Bearing Clearance 0.048-0.024 mm Main Bearing Cap Bolts ---- Refer to Engine; Service and Repair; Assembly for tightening specifications and sequences. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 2755 Crankshaft Main Bearing: Service and Repair For service procedures relating to this component, please refer to Engine; Service and Repair. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Main Bearing Journal Diameter 67.483 - 67.503 mm Maximum Out-of-Round 0.0075 mm Between Cross Sections Maximum Taper (Straightness) 0.004 mm Runout 0.05 mm HM of center journals when located on front and rear journal 3 Places Clearance-Crankshaft Journal to Main Bearing Clearance 0.048 - 0.024 mm Connecting Rod Journal Diameter 53.003 - 52.983 mm Maximum Out-of-Round 0.0075 mm Between Cross Sections Maximum Taper 0.004 mm Crankshaft End Play 0.075 - 0.377 mm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 2759 Crankshaft: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair Engine Block Heater: Service and Repair Removal 1. Drain the engine cooling system. 2. Disconnect the (A) block heater wire extension from the (B) block heater wiring and remove. 3. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Failure to follow these instructions may result in personal injury. Raise and support the vehicle. 4. Disconnect the (A) block heater wiring from the (B) block heater. 5. Remove the block heater. 1 CAUTION: Do not loosen the screw more than necessary for removal. Loosen the screw. 2 Twist and slide the block heater to release the retainer clip and remove. Discard the retainer clip. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Page 2763 1. Note: To ease installation, coat the block heater sea] and the cylinder block hole with Premium Long Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-13. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft damper pulley bolt Refer to Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2767 Harmonic Balancer - Crankshaft Pulley: Service and Repair Removal 1. Remove the engine cooling fan and fan shroud. 2. Remove the drive belt. 3. Remove the crankshaft pulley bolt. 4. Use the Crankshaft Damper Remover to remove the crankshaft pulley. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2768 1. Note: If not secured within four minutes, sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-l9A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone to the woodruff key slot on the crankshaft pulley. Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4. 2. Use the Crankshaft Damper Replacer to install the crankshaft pulley. 3. Install the bolt and washer. Tighten the bolt in four stages. - Stage 1:Tighten to 90 Nm (66.15 ft. lbs.). - Stage 2: Loosen the bolt. - Stage 3: Tighten to 47 - 53 Nm (34 - 39 ft. lbs.). - Stage 4: Tighten an additional 85 - 90 degrees. 4. Install the drive belt. 5. Install the engine cooling fan and the fan shroud. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston Diameter (Grade 2) at Right Angle to Pin Bore 90.180 +/- 0.005 mm Piston to Bore Clearance (at Grade Size) 0.020 - 0.045 mm Ring Groove Width Top 1.53 - 1.55 mm Intermediate 1.52 - 1.54 mm Oil Control 3.030 - 3.050 mm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 2772 Piston: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Service and Repair Piston Pin: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Ring Gap Top 0.13 - 0.28 mm Intermediate 0.25 - 0.40 mm Oil Control 0.15 - 0.65 mm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 2779 Piston Ring: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer does not indicate whether this vehicle has adjustable or non-adjustable valves. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD . Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 2787 Fuel Pressure Release: Service and Repair SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. ^ This will drain some fuel out of the system. Place the fuel in a suitable container. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 2788 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: Customer Interest Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2797 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2798 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2804 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2805 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2806 Rocker Arm Assembly: Service and Repair Special Tools Removal 1. Remove the valve cover. 2. Position the piston of the cylinder being repaired at the bottom of the stroke. 3. Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal damage. 4. Note: The roller followers are positional. Mark the followers for installation in their original locations. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 2807 Use the Valve Spring Compressor to compress the valve springs and remove the cam roller followers. Installation 1. Use the (A) Valve Spring Compressor to compress the (B) valve spring and install the (C) camshaft roller followers in their original locations. 2. Remove the Valve Spring Spacer. 3. Install the valve covers. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Valve cover bolts 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH Valve Cover: Service and Repair LH Removal 1. Disconnect the battery ground cable. 2. Remove the engine air cleaner and the air cleaner outlet tube. 3. Position the power steering fluid reservoir and bracket aside. 1 Remove the bolts. 2 Position the power steering fluid reservoir and bracket aside. 4. Note: 4.6L engine shown; 5.4L engine similar. Remove the crankcase ventilation tube from the valve cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2813 4.6L Engine 5.4L Engine 5. Remove the EGR valve-to-exhaust manifold tube. - Disconnect the upper and lower EGR valve-to-exhaust manifold tube fittings. - Disconnect the two differential pressure feedback EGR hoses. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2814 6. Disconnect the LH fuel injector electrical connections. 7. Disconnect the LH ignition coil electrical connections. 8. Disconnect the Camshaft Position (CMP) sensor. 9. Lift the engine sensor control wiring harness off of the valve cover studs. 10. Note: The intake manifold is removed for clarity. Note: The bolts are part of the valve cover and should not be removed. Remove the LH valve cover. - Fully loosen the bolts and remove the valve cover. - Inspect the valve cover gasket and clean the mating surface of the cylinder head. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2815 1 Note: If not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply a bead of silicone in two places where the engine front cover meets the cylinder head. Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4. 2. Position the (A) valve cover and the valve cover gasket on the (B) cylinder head, and loosely install the bolts. Romeo Engine Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2816 Windsor Engine 3. Tighten the bolts in the sequence shown. 4. Position the engine sensor control wiring harness onto the valve cover studs. 5. Connect the CMP electrical connector. 6. Connect the LH ignition coil electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2817 7. Connect the LH fuel injector electrical connectors. 8. Connect the EGR valve to exhaust manifold tube upper fitting. On 4.6L engines, tighten both fittings starting the top in two stages. Stage 1: Hand-tighten. - Stage 2: Tighten to 35-45 Nm (26-33 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2818 On 5.4L engines, tighten both fittings starting at the top in two stages. Stage 1: Hand-tighten. - Stage 2: Tighten to 40-60 Nm (30-44 ft. lbs.). 9. Note: 4.6L engine shown; 5.4L engine similar. Connect the crankcase ventilation tube to the valve cover. 10. Install the engine Air Cleaner (ACL) and air cleaner outlet tube. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2819 11. Install the power steering fluid reservoir and bracket. 1 Position the power steering fluid reservoir and bracket. 2 Install the bolts. 12. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2820 Valve Cover: Service and Repair RH Removal 1. Disconnect the battery ground cable. 2. Disconnect the crankcase ventilation hose. 3. Disconnect the two fuse block cable ends from the starter relay. 4. Disconnect the two 42-pin bulkhead electrical connections and remove them from the junction block bracket. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2821 5. Remove the bolts and the junction block bracket. 6. Disconnect the RH fuel injector electrical connections. 7. Disconnect the RH ignition coil electrical connections. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2822 8. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Note: The bolts are part of the valve cover and cannot be removed. Note: Windsor engine shown; Romeo engine similar. Loosen the bolts and remove the valve cover. Remove the valve cover gasket. Clean and inspect the mating surface. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Note: If the valve cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply the silicone in two places where the engine front cover meets the cylinder head. Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2823 2. Position the valve cover on the cylinder head and loosely install the valve cover bolts. Romeo Engine Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2824 Windsor Engine 3. Tighten the bolts in the sequence shown. 4. Connect the two 42-pin bulkhead electrical connections. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > LH > Page 2825 5. Connect the two fuse cable leads to the starter relay. 6. Install the crankcase ventilation hose. 7. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications Valve Guide Inner Diameter 0.020-0.095 mm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Valve Seat Width Intake 1.3 - 1.5 mm Valve Seat Width Exhaust 2.1 - 1.9 mm Valve Seat Angle 45.00 - 44.50 deg Valve Seat Runout (T.I.R.) 0.025 mm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Valve Spring Compression Pressure Intake 720 - 800 N at 28.02 mm Exhaust 720 - 800 N at 28.02 mm Valve Spring Free Length Intake 53.37 mm Exhaust 53.37 mm Valve Spring Installed Pressure Length Intake 287.19 - 321.19 N at 42.56 mm Exhaust 287.19 - 321.19 N at 42.56 mm Valve Springs Installed Pressure Length Service Limit Intake 5% Pressure Loss at 28.80 mm Exhaust 5% Pressure Loss at 28.80 mm Valve Springs - Out of Square Limit Intake 2.0 deg Exhaust 2.0 deg Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 2835 Valve Spring: Service and Repair Special Tools Removal 1. Remove the camshaft roller followers. 2. Position the piston at the top of the stroke. 3. Remove the spark plug and install compressed air in the cylinder to hold both valves in position. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal. 4. Use the Valve Spring Compressor to compress the valve springs. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 2836 5. Remove the (A) valve spring retainer keys, the (B) valve spring retainers, and the (C) valve spring. Installation 1. Position the valve spring and the valve spring retainers. 2. Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal damage. 3. Use the Valve Spring Compressor to compress the valve spring. Install the valve spring retainer keys. 4. Install the camshaft roller followers. 5. Install the spark plug. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold Valve: Customer Interest Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold > Page 2845 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold > Page 2846 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Valve: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2852 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2853 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Page 2854 Valve: Specifications Valve Stem Guide Clearance Intake 0.069 - 0.020 mm Exhaust 36.0 mm Valve Head Diameter Intake 44.63 - 44.37 mm Exhaust 34.12 - 33.88 mm Valve Face Runout (Limit) 0.05 mm Valve Face Angle 45.75 - 45.25 deg Valve Stem Diameter Intake 6.995 - 6.975 mm Exhaust 6.970 - 6.949 mm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Page 2855 Valve: Service and Repair Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of Subassemblies". See: Service and Repair "General Procedures" typically covers cleaning and inspection of the following components as part of engine overhaul: - Crankshaft & Crankshaft Bearings - Camshaft & Crankshaft Bearings - Cylinder Head - Valve train components (Valves, Seats, Springs, etc) - Piston, Piston Pin, Connecting Rod - Cylinder Block & Bore "Disassembly and Assembly of Subassemblies" typically covers service of the following components: - Cylinder Head - Piston, Piston Pin, & Connecting Rod Assemblies Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If an internal engine component does not have a separate service procedure, the manufacturer did not provide one. Please refer to Engine Service and Repair for available service procedures. See: Service and Repair Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Locations Drive Belt: Locations Accessory Drive 4.6L, 5.4L(2V), 5.4L(4V) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Locations > Page 2860 Drive Belt: Diagrams Accessory Drive 4.6L, 5.4L(2V), 5.4L(4V) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Locations > Page 2861 Drive Belt: Description and Operation Accessory Drive 4.6L, 5.4L(2V), 5.4L(4V) The accessory drive consists of the: - drive belt (8620). - generator pulley. - power steering pump pulley. - crankshaft pulley. - A/C clutch pulley. - belt idler pulley. - drive belt tensioner. - water pump pulley. The accessory drive: - has a single serpentine drive belt. - has an automatic drive belt tensioner. - does not require adjustment. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview 1. Verify customer concern by running the engine. 2. Inspect the drive belt for chunking, fraying and wear. 3. Check the drive belt for correct routing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 2864 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 2865 Drive Belt: Component Tests and General Diagnostics Belt Tension Note: Drive belt tension is not adjustable. The drive belt tensioner automatically adjusts drive belt tension. Belt Tensioner, Automatic Check the automatic drive belt tensioner: 1. With the engine off, check for proper drive belt routing. Service as required. 2. Rotate the drive belt tensioner and check for a binding or frozen condition. Replace components as required. V-Ribbed Belt With Cracks (Acceptable) V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable) Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys. Non-standard replacement drive belts may track differently or improperly. If a replacement drive belt tracks improperly, replace it with an original equipment drive belt to avoid performance failure or loss of drive belt. With the engine running, check drive belt tracking. If the (A) edge of the drive belt rides beyond the edge of the pulleys, noise and premature wear may occur. Make sure the (B) drive belt rides correctly on the pulley. If a drive belt tracking condition exists, proceed with the following: Visually check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. This will result in chirp and squeal noises. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 2866 - With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the pulley forward faces) for excessive wobble. Replace components as required. - Check all accessories, mounting brackets and the drive belt tensioner for any interference that would prevent the component from mounting properly. Correct any interference condition and recheck the drive belt tracking. - Tighten all accessories, mounting brackets, and drive belt tensioner retaining hardware to specification. Recheck the drive belt tracking. Drive Belt Noise/Flutter Note: Tensioner is shown in free-state position against arm travel stops. Drive Belt Tensioner/Belt Length Indicator Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a damaged pulley or an improperly aligned pulley. To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a straightedge to the crankshaft pulley, look for accessory pulleys out of position in the fore/aft direction or at an angle to the straightedge. Drive belt squeal is an intermittent noise that occurs when the drive belt slips on a pulley during certain conditions, such as: engine start up, rapid engine acceleration, or A/C clutch engagement. Drive belt squeal can occur under certain conditions: If the A/C discharge pressure goes above specifications: + the A/C system is overcharged. + the A/C condenser core airflow is blocked. - If the A/C OFF equalized pressure (the common discharge and suction pressure that occurs after several minutes) exceeds specifications. - If any of the accessories are damaged, have a worn or damaged bearing, internal torsional resistance above normal. All accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory. - If fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air conditioning system lubricant. If fluid does get on the drive belt during service, clean the drive belt with soap and water and thoroughly rinse with clean water. The drive belt does not have to be Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 2867 replaced if no apparent damage has occurred. - Note: The drive belt tensioner arm should rotate freely without binding. If the drive belt is too long. A drive belt that is too long will allow the drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. If the drive belt tensioner indicator is outside the installation wear range window, replace the drive belt. - If the drive belt tensioner is worn or damaged. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2868 Drive Belt: Adjustments Note: Drive belt tension is not adjustable. The drive belt tensioner automatically adjusts drive belt tension. Belt Tensioner, Automatic Check the automatic drive belt tensioner: 1. With the engine off, check for proper drive belt routing. Service as required. 2. Rotate the drive belt tensioner and check for a binding or frozen condition. Replace components as required. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2869 Drive Belt: Service and Repair Accessory Drive Removal 4.6L, 5.4L(2V), 5.4L(4V) 1. Rotate the drive belt tensioner clockwise and remove the drive belt. Installation 4.6L, 5.4L(2V), 5.4L(4V) 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Drive Belt Tension Bolts 18 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 2873 Drive Belt Tensioner: Service and Repair Removal 1. Remove the drive belt. 2. Remove the bolts and the drive belt tensioner. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications Engine Mount: Specifications Motor mount to cylinder block bolts 39 - 53 ft.lb Motor mount through bolts 50 - 68 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH Engine Mount: Service and Repair LH Special Tools Removal 1. Remove the fan shroud. 2. Remove the generator. 3. Install the 3-Bar Modular Engine Support Bracket on the engine using the generator mounting holes. 4. Raise the vehicle. 5. Remove the LH motor mount bolt. 6. Loosen the RH motor mount bolt. 7. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2879 8. Install the 3-Bar Engine Support and raise the engine. 9. Raise the vehicle on the hoist. 10. Remove the bolts and remove the engine mount. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2880 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2881 Engine Mount: Service and Repair RH Special Tools Removal 1. Remove the fan shroud. 2. Remove the generator. 3. Install the 3-Bar Modular Engine Support Bracket on the engine using the generator mounting holes. 4. Raise the vehicle. 5. Remove the starter motor. 6. Remove the RH motor mount bolt. 7. Loosen the LH motor mount bolt. 8. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2882 9. Install the 3-Bar Engine Support and raise the engine. 10. Raise the vehicle on the hoist. 11. Remove the RH bolts and remove the engine mount. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2883 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications Idler Pulley: Specifications Drive belt idler pulley bolt 18 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications > Page 2887 Idler Pulley: Service and Repair Removal 1. Remove the drive belt. 2. Remove bolt and belt idler pulley. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Factory information does not provide an oil pressure specification for this vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications Engine Oil Dip Stick - Dip Stick Tube: Specifications Oil level indicator tube bolt 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications > Page 2895 Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Removal 1. Remove LH exhaust manifold. 2. Remove the oil level indicator. 3. Remove the bolt. 4. Remove the oil level indicator tube. 5. Note: Lubricate the new O-ring seal with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Replace the O-ring seal. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications > Page 2896 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications Oil pan drain plug 98 - 143 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2904 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2905 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2906 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications 4.6L and 5.4L Engine Automatic Transmission ...................................................................................................................... ................................................... 6.675 quarts ± 0.125 Manual Transmission .......................................................................................................................... ................................................... 6.425 quarts ± 0.125 5.4L (4V) Engine .................................................................................................................................. .......................................................... 6.62L (7.0 qt)* * With filter. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2909 Engine Oil: Fluid Type Specifications Engine Oil ............................................................................................................................................ ............................................................... SAE 5W-20 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications Oil Cooler: Specifications Oil cooler assembly to oil filter adapter bolts 41 - 44 ft.lb Oil cooler insert 41 - 44 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications > Page 2913 Oil Cooler: Service and Repair Removal 1. Raise and support vehicle. 2. Remove the drain plug and drain the engine oil. 3. Drain the coolant. 4. Note: Make sure all O-ring seals are in place. Remove the oil bypass filter. 5. Remove the oil cooler insert, and remove the oil cooler. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications > Page 2914 1. Install the oil cooler insert. 2. Install the oil bypass filter. 3. Install the drain plug. 4. 1,lower the vehicle. 5. Fill the engine with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 6. Fill the engine coolant. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil filter 11 - 12 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications Oil Filter Adapter: Specifications Oil filter adapter bolt 15 - 22 ft.lb Oil filter adapter nut 30 - 40 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications > Page 2921 Oil Filter Adapter: Service and Repair Removal 1. Raise and support the vehicle. 2. Remove the lower radiator hose. 3. Remove the front drive axle assembly. 4. Remove the drain plug and drain the engine oil. 5. If the vehicle does have an oil cooler, remove the oil cooler. 6. Disconnect the oil pressure sender electrical connector. 7. Remove the four bolts and the oil filter adapter. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications > Page 2922 1. Install a new oil filter adapter gasket. 2. Position the Oil filter adapter and install the four bolts. - Install a new oil filter adapter gasket. - Position the oil filter adapter and install the four bolts. 3. Connect the oil pressure sender electrical connector. 4. If the vehicle is equipped with an oil cooler, install the oil cooler. 5. Install the drain plug. 6. Install the front drive axle assembly. 7. Install the lower radiator hose. 8. Lower the vehicle. 9. Fill the engine with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Specifications Oil Line: Specifications Oil line connector adapter assembly bolt 15 - 22 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil pan bolts Refer to the procedure in this section Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2929 Oil Pan: Service and Repair Removal 1. CAUTION: The air suspension switch must be turned off prior to raising the vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which could result in shifting of the vehicle during the repair operation. Turn the air suspension switch off. 2. Raise the vehicle on the hoist. 3. Drain the engine oil. 4. Support the front axle housing with a jack stand. 5. Remove front axle housing support. - Remove the front axle mount bolt. - Remove the axle support bolts. - Remove the axle support. 6. CAUTION: Use care when lowering the front axle housing, or the vacuum lines to the axle solenoid may become disconnected or damaged. Remove the right and front axle housing mount bolts and lower the axle to allow clearance for the oil pan to be removed. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2930 7. Remove the oil pan. 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 pan gasket. Clean the sealing surfaces. Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow the surfaces to dry for four minutes or until there is no sign of wetness, whichever is longest. Failure to do so can cause future oil leaks. Installation 1. Note: If the oil pan and gasket are not secured within four minutes of sealer application, the sealant must be removed and the sealing surfaces cleaned with Metal Surface Cleaner F4AZ-l9A536-RA or equivalent meeting Ford specification WSE-M5B392-A. Apply Silicone Gasket and Sealant F7AZ-19554-EA or equivalent in two places. 2. Apply Silicone Gasket and Sealant F7AZ-19554-EA or equivalent in two places. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2931 3. Position the new oil pan gasket and the oil pan and loosely install the bolts. 4. Tighten the bolts in three stages in the sequence shown. - Stage 1: Tighten to 2 Nm (18 inch lbs.). - Stage 2: Tighten to 20 Nm (15 ft. lbs.). - Stage 3: Tighten an additional 60 degrees. 5. Position the front axle housing and loosely install the bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2932 6. Position the axle support and install the bolts. 7. Tighten the bolts. 8. Remove the jack stand. 9. Lower the vehicle. 10. Fill the engine with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C13-G. 11. Start the engine and inspect for leaks. 12. Turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Gauge: All Technical Service Bulletins Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 2941 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Gauge: Customer Interest Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 2947 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Page 2948 Oil Pressure Gauge: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Sender: Customer Interest Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 2957 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Sender: All Technical Service Bulletins Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 2963 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Specifications Oil Pressure Sensor: Specifications Oil Pressure sensor 107 - 142 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications Oil Pick Up/Strainer: Specifications Oil pump screen cover and tube bolts 71 - 106 in.lb Oil pump screen cover and tube spacer 15 - 22 ft.lb Oil pump screen cover and tube spacer bolt 15 - 22 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications > Page 2970 Oil Pick Up/Strainer: Service and Repair Removal 1. Remove the oil pan. 2. Remove the three (A) bolts and the (B) oil pump screen cover and tube. Installation 1. Note: Lubricate the new O-ring seal with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Clean and inspect the mating surfaces and replace the O-ring seal 2. Install the oil pump screen cover and tube and install the bolts. 3. Install the oil pan. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Factory information does not provide an oil pressure specification for this vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Upper Intake Manifold to Cylinder Head Bolts Stage 1 18 in.lb Stage 2 89 in.lb Throttle Body Adapter Bolts Stage 1 89 in.lb Stage 2 Additional 90 degrees Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2978 Intake Manifold: Service and Repair Removal WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. 1. Disconnect the battery ground cable. 2. Relieve the fuel system pressure. 3. Drain the engine cooling system. 4. Remove the engine Air Cleaner (ACL) and the air cleaner outlet tube. 5. Compress and slide the hose clamp and disconnect the upper radiator hose. 6. Remove the accelerator cable snow shield. 1 Remove the bolts. 2 Remove the accelerator cable snow shield. 7. Disconnect the throttle body cam. 1 Disconnect the accelerator cable. 2 Disconnect the speed control actuator cable. 3 Remove the accelerator return spring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2979 8. Remove the accelerator cable bracket bolts and position the bracket and cables aside. 9. Disconnect the vapor management valve hose. 10. Remove the crankcase ventilation tube and the Idle Air Control (IAC) valve fresh air tube. 11. Disconnect the Exhaust Gas Recirculation (EGR) valve vacuum line and the main vacuum harness. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2980 12. Disconnect the throttle position sensor electrical connector and the engine vacuum regulator connector. 13. Disconnect the fuel pressure regulator vacuum line. 14. Disconnect the vapor management valve vacuum line. 15. Disconnect the differential pressure feedback EGR. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2981 16. Remove the nut and disconnect the brake booster vacuum line and bracket. 17. Disconnect the fuel lines. 18. Disconnect the idle air control motor electrical connector. 19. Position the EGR valve to exhaust manifold tube aside. - Disconnect the upper fitting. - Loosen the lower fitting. - Disconnect the two vacuum lines. - Position the tube aside. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2982 20. Remove the four bolts and remove the throttle body adapter. 21. Disconnect and remove the Positive Crankcase Ventilation (PCV) hose. 22. Position the power steering reservoir aside. - Remove the upper bolt. - Remove the lower bolts. - Position the reservoir aside. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2983 23. Disconnect the eight fuel injectors. 24. Disconnect and remove the eight ignition coils. 25. Remove the generator. 26. Disconnect the heater hose. 27. Disconnect the two radio interference capacitors. 28. Remove the water thermostat. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2984 29. Remove the nine bolts. 30. Remove the upper intake manifold. 1 Lift the intake manifold. 2 Disconnect the intake manifold tuning valve connector. 3 Remove the intake manifold and discard the gaskets. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2985 31. If required, remove the bolts and the water crossover. Installation 1. CAUTION: Do not use metal scrapers, power abrasive discs or any abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraper only. Clean all the sealing surfaces. 2. If removed, install the water crossover. 3. Install the intake manifold. 1 Position the new intake manifold gaskets. 2 Position the upper intake manifold. 3 Loosely install nine bolts. 4. Install the water thermostat. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2986 5. Tighten the 11 bolts in two stages in the sequence shown. - Stage 1: Tighten to 2 Nm (18 inch lbs.). - Stage 2: Tighten to 10 Nm (89 inch lbs.). 6. Connect the two radio ignition interference capacitor electrical connectors. 7. Connect the heater hose. 8. Install the generator. 9. Install and connect eight ignition coils. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2987 10. Connect the eight fuel injector electrical connectors. 11. Install the power steering reservoir. - Position the reservoir. - Install the two lower bolts. - Install the upper bolt. 12. Install the PCV hose. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2988 13. Install the throttle body adapter and the four bolts. Tighten the bolts in two stages. Stage 1: Tighten to 10 Nm (89 inch lbs.) - Stage 2: Tighten an additional 90 degrees. 14. Install the EGR valve to exhaust manifold tube. - Hand-tighten the fittings. - Tighten the upper fitting. - Tighten the lower fitting. - Connect the two vacuum hoses. 15. Connect the idle air control motor. 16. Connect the fuel lines. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2989 17. Connect the brake booster vacuum line and bracket and install the nut. 18. Connect the differential pressure feedback EGR connections. 19. Connect the vapor management valve vacuum line. 20. Connect the fuel pressure regulator vacuum line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2990 21. Connect the throttle position sensor connector and the engine vacuum regulator connector. 22. Connect the EGR valve the main vacuum harness vacuum connections. 23. Install the crankcase ventilation tube and the IAC fresh air tube. 24. Connect the vapor management hose. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2991 25. Install the accelerator cable bracket and the bolts. 26. Connect the throttle body cam. 1 Connect the accelerator cable. 2 Connect the speed control actuator cable. 3 Install the throttle return spring. 27. Install the accelerator cable snow shield and the bolts. 28. Connect the upper radiator hose and position the clamp. 29. Install the engine air cleaner and the air cleaner outlet tube. 30. Connect the battery ground cable. 31. Fill and bleed the engine cooling system. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Gauge: Customer Interest Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 3001 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Gauge: All Technical Service Bulletins Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 3007 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Page 3008 Oil Pressure Gauge: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Specifications Crankshaft Main Bearing Seal: Specifications Rear main oil seal retainer bolts 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Oil Seal With Retainer Plate Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal With Retainer Plate Special Tools Removal 1. Remove the transmission. 2. Remove the oil pan. 3. Remove the flywheel. 4. Use the (A) Rear Crank Slinger Remover and the (B) Slide Hammer to remove the (C) rear oil seal slinger. 5. Use the (A) Rear Crankshaft Seal Remover and the (B) Slide Hammer to remove the (C) rear main seal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Oil Seal With Retainer Plate > Page 3015 6. If the oil dye leak test reveals a leak behind the retainer, remove the six bolts and the crankcase rear oil seal retainer. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Note: Clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer, failure to follow this procedure can cause future oil leakage. Clean and inspect the mating surface. 2. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Note: If the rear crankshaft seal retaining plate is not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Note: The silicone must be applied on the groove along the retainer plate. Apply a 4 mm (0.16 inch) bead of silicone around the rear oil seat retainer sealing surface. Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4. 3. Install the rear oil seal retainer and loosely install the six bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Oil Seal With Retainer Plate > Page 3016 4. Tighten the bolts in the sequence shown. 5. Note: Lubricate the inner lip of the rear crankshaft seal with Super Premium SAE 5W-30 Motor Oil X0-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Use the Rear Crankshaft Seal Replacer and the Rear Crankshaft Seal Adapter to install the rear main seal. 6. With the Rear Crankshaft Seal Adapter still installed, use the Rear Crankshaft Slinger Replacer and the Rear Crankshaft Seal Replacer to install the rear main seal slinger. 7. Install the flywheel. 8. Install the oil pan. 9. Install the transmission. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Oil Seal With Retainer Plate > Page 3017 Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Seal Special Tools Removal 1. Remove the transmission. 2. Remove the flywheel. 3. Use the (A) Rear Crankshaft Slinger Remover and the (B) Slide Hammer to remove the (C) rear oil seal slinger. 4. Use the (A) Rear Crankshaft Seal Remover and the (B) Slide Hammer to remove the (C) rear main seal. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Crankshaft Rear Oil Seal With Retainer Plate > Page 3018 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Note: Lubricate the inner lip of the rear crankshaft seal with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Use the Rear Crankshaft Seal Replacer and the Rear Crankshaft Seal Adapter to install the rear main seal. 2. With the Rear Crankshaft Seal Adapter still installed, use the Rear Crankshaft Slinger Replacer and the Rear Crankshaft Seal Replacer to install the rear main seal slinger. 3. Install the flywheel. 4. Install the transmission. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket Cylinder Head Gasket: Customer Interest Engine - Oil Leak From R/H Cylinder Head Gasket Article No. 03-6-2 03/31/03 ENGINE - CYLINDER HEAD DECK LEAK - 4.6 AND 5.4L ENGINES - NEW "SERVICE-ONLY" GASKET AND CYLINDER HEAD KITS AVAILABILITY FORD: 1999-2002 CROWN VICTORIA, MUSTANG 1999-2001 E SERIES, EXPEDITION, F-150, SUPER DUTY F SERIES 2000-2001 EXCURSION LINCOLN: 1999-2002 TOWN CAR 1998-1999 NAVIGATOR MERCURY: 1999-2002 GRAND MARQUIS Article 02-22-7 is being republished in its entirety to update the Model Year and Model Line coverage. ISSUE Some vehicles equipped with the Romeo built 4.6L 2V engine or 5.4L 2V Windsor and 5.4L Supercharged engine may exhibit an oil leak or oil weepage from the cylinder head gasket at the right hand rear or the left hand front of the engine. Oil weepage is not considered detrimental to engine performance or durability. An oil leak may be caused by metal chip debris lodged between the head gasket and the block, chip debris between the cylinder head and the head gasket, or by damage to the cylinder head sealing surface that occurred during the manufacturing process. ACTION Once an oil leak is verified with a black light test at the head gasket joint, replacement of the head gasket can be performed. If the head was damaged by chip contamination, the head should be replaced. A revised "Service-Only" gasket is now released for both of these cases. SERVICE INFORMATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 3027 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 3028 Cylinder heads damaged by brinnelling (depression marks from original gasket) of the head may still be reusable. The revised "Service-Only" gasket has a feature by which the embossed sealing area does not follow the same sealing path as the original gasket. This area is surrounding the High Pressure Oil Feed (HPOF) area. It is triangular in shape and is found in the rear of the passenger side cylinder head, or, in the front of the drivers side cylinder head (Figure 1 and Figure 2). Required for service are: ^ A straightedge (machine flatness toleranced to 0.0002" per foot in length) (available from Snap-On or as provided by Ford Motor Company) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 3029 ^ Motorcraft Silicone Gasket Remover (ZC-30) ^ Metal Surface Prep (ZC-31) ^ Service-only gasket (3U7Z-6051-BA for drivers side and/or 3U7Z-6051-AA for passenger side) with the new embossed area The engine should be allowed to cool before removing the head or warpage may occur in deck flatness. The cylinder head and block decks should be cleaned before performing a flatness check. Dark metal stains below the surface of the metal are normal. Do not attempt to polish off the stains with grinders or scrapers. Use a plastic scraper (or plastic ice scraper or equivalent) to pull away any residual silicone RTV with ZC-30 and ZC-31 applied in sequence. The Workshop Manual and Service Labor Time Standards have been recently updated for both cars and truck using 4.6L 2V and 5.4L 2V and Supercharged 5.4L engines. These include instructions to remove the engine prior to removing the cylinder head. Service Labor Time Standards allow for extra time in engine removal and cylinder head deck leak repair out of vehicle. Cylinder Head Kits are available on most applications. Refer to the current Parts Catalog Listing for applicability. Cylinder Head Kits include: ^ Complete Head assembly, with Cam and Valves ^ Head Bolts ^ Service Only Head Gasket ^ Both Intake Gaskets Exhaust Gasket ^ One Rocker Cover Gasket ^ One set of Exhaust Studs and Nuts If it is found that only one head is leaking, it is not necessary to remove the other head Only repair the side for which leakage occurs. For detailed information on these subjects refer to previous articles on general cylinder head gasket repairs, machining of aluminum heads and blocks, gasket cleaners/removers, and straightedge procedures. Parts Block OTHER APPLICABLE ARTICLES: 01-12-2, 01-21-10, 02-1-4, 02-11-4, 02-21-13, 02-2-3, 02-17-2 SUPERSEDES: 02-22-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 490000, 497000, 499000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification Cylinder Head Gasket: All Technical Service Bulletins Engine - Reman Engine Head Gasket Identification TSB 06-18-16 09/18/06 IDENTIFYING THE CORRECT REPLACEMENT HEAD GASKET FOR CERTAIN REMANUFACTURED ENGINES - SERVICE TIP FORD: 1999-2006 Mustang, Mustang, Mustang, Mustang, Mustang, Mustang 2000-2005 Thunderbird 2001-2005 Taurus 2001-2006 Crown Victoria, Crown Victoria 2005 Five Hundred, Freestyle 1997-2005 Expedition 1997-2006 E-Series, Explorer, F-150, F-Super Duty 1999-2003 Windstar 1999-2004 F-53 Motorhome Chassis 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape, Escape, Explorer Sport Trac, Ranger 2004-2005 Freestar, Freestar 2006 F-53 Motorhome Chassis LINCOLN: 2000-2006 Lincoln LS 2001-2002 Continental 2001-200 Town Car 1998-2004 Navigator, Navigator 2003-2004 Aviator 2006 Mark LT MERCURY: 2001 Cougar 2001-2005 Sable 2001-2006 Grand Marquis 2003-2006 Marauder 2005 Montego 1997-2006 Mountaineer 2004-2005 Monterey 2005 Mariner ISSUE On various vehicles when servicing the head gasket on certain Ford remanufactured engines, it is critical to determine the type of remanufactured engine that is being serviced, in order to identify the correct replacement gasket. ACTION Follow the Service Procedure to help identify if the vehicle is equipped with a SID (for originally equipment level thickness head gasket) or OVR (for oversized service level thicker head gasket) remanufactured engine when replacing a head gasket. SERVICE PROCEDURE Use this TSB to help identify if the vehicle is equipped with a STD or OVR remanufactured engine when replacing a head gasket. This will ensure that you obtain the proper head gasket (thicker for OVR-oversized) for the engine you are repairing, as the engine may have milled engine block deck, milled cylinder head deck, or an over sized bore in the cylinders. This information will be needed when ordering parts. The parts catalogs already reflect the correct service numbers, as long as this additional information is available. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification > Page 3035 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification > Page 3036 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification > Page 3037 For certain remanufactured engines, the long block assembly will be uniquely identified with a build date, reman code, service part number, and serial number. This metal tag will be marked with STD, or with OVR (Figures 1-6). WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket Cylinder Head Gasket: All Technical Service Bulletins Engine - Oil Leak From R/H Cylinder Head Gasket Article No. 03-6-2 03/31/03 ENGINE - CYLINDER HEAD DECK LEAK - 4.6 AND 5.4L ENGINES - NEW "SERVICE-ONLY" GASKET AND CYLINDER HEAD KITS AVAILABILITY FORD: 1999-2002 CROWN VICTORIA, MUSTANG 1999-2001 E SERIES, EXPEDITION, F-150, SUPER DUTY F SERIES 2000-2001 EXCURSION LINCOLN: 1999-2002 TOWN CAR 1998-1999 NAVIGATOR MERCURY: 1999-2002 GRAND MARQUIS Article 02-22-7 is being republished in its entirety to update the Model Year and Model Line coverage. ISSUE Some vehicles equipped with the Romeo built 4.6L 2V engine or 5.4L 2V Windsor and 5.4L Supercharged engine may exhibit an oil leak or oil weepage from the cylinder head gasket at the right hand rear or the left hand front of the engine. Oil weepage is not considered detrimental to engine performance or durability. An oil leak may be caused by metal chip debris lodged between the head gasket and the block, chip debris between the cylinder head and the head gasket, or by damage to the cylinder head sealing surface that occurred during the manufacturing process. ACTION Once an oil leak is verified with a black light test at the head gasket joint, replacement of the head gasket can be performed. If the head was damaged by chip contamination, the head should be replaced. A revised "Service-Only" gasket is now released for both of these cases. SERVICE INFORMATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 3042 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 3043 Cylinder heads damaged by brinnelling (depression marks from original gasket) of the head may still be reusable. The revised "Service-Only" gasket has a feature by which the embossed sealing area does not follow the same sealing path as the original gasket. This area is surrounding the High Pressure Oil Feed (HPOF) area. It is triangular in shape and is found in the rear of the passenger side cylinder head, or, in the front of the drivers side cylinder head (Figure 1 and Figure 2). Required for service are: ^ A straightedge (machine flatness toleranced to 0.0002" per foot in length) (available from Snap-On or as provided by Ford Motor Company) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 3044 ^ Motorcraft Silicone Gasket Remover (ZC-30) ^ Metal Surface Prep (ZC-31) ^ Service-only gasket (3U7Z-6051-BA for drivers side and/or 3U7Z-6051-AA for passenger side) with the new embossed area The engine should be allowed to cool before removing the head or warpage may occur in deck flatness. The cylinder head and block decks should be cleaned before performing a flatness check. Dark metal stains below the surface of the metal are normal. Do not attempt to polish off the stains with grinders or scrapers. Use a plastic scraper (or plastic ice scraper or equivalent) to pull away any residual silicone RTV with ZC-30 and ZC-31 applied in sequence. The Workshop Manual and Service Labor Time Standards have been recently updated for both cars and truck using 4.6L 2V and 5.4L 2V and Supercharged 5.4L engines. These include instructions to remove the engine prior to removing the cylinder head. Service Labor Time Standards allow for extra time in engine removal and cylinder head deck leak repair out of vehicle. Cylinder Head Kits are available on most applications. Refer to the current Parts Catalog Listing for applicability. Cylinder Head Kits include: ^ Complete Head assembly, with Cam and Valves ^ Head Bolts ^ Service Only Head Gasket ^ Both Intake Gaskets Exhaust Gasket ^ One Rocker Cover Gasket ^ One set of Exhaust Studs and Nuts If it is found that only one head is leaking, it is not necessary to remove the other head Only repair the side for which leakage occurs. For detailed information on these subjects refer to previous articles on general cylinder head gasket repairs, machining of aluminum heads and blocks, gasket cleaners/removers, and straightedge procedures. Parts Block OTHER APPLICABLE ARTICLES: 01-12-2, 01-21-10, 02-1-4, 02-11-4, 02-21-13, 02-2-3, 02-17-2 SUPERSEDES: 02-22-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 490000, 497000, 499000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures Technical Service Bulletin # 02-1-4 Date: 020121 Engine Head Gasket - Approved Replacement Procedures Article No. 02-1-4 01/21/02 ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES FORD: 1992-1997 THUNDERBIRD 1992-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 2000-2002 FOCUS 1995-2002 WINDSTAR 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1992-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1992-1997 COUGAR 1992-1999 TRACER 1992-2002 GRAND MARQUIS, SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER ISSUE Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or scratches and dents at the head to block mating surfaces. ACTION Refer to the following Service Information for recommended gasket sealing surface preparation procedures. If the engine diagnosis points to a faulty head gasket (leaks oil, leaks coolant, oil or coolant contamination, or air in coolant), thorough cleaning procedures are necessary for a successful head gasket repair. Diagnosis and post-repair confirmation can be done successfully utilizing leak detection methods such as a black light dye process. SERVICE PROCEDURE To sum up, a successful leak repair depends on: ^ Accurate diagnosis of the leak using Ford-recommended test equipment and procedures ^ Surface preparation and gasket installation using the approved tools, cleaners, and methods ^ Exercising CARE and CLEANLINESS during disassembly/assembly of components ^ Use of genuine Ford OEM replacement parts ^ Use of a Ford Remanufacturer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 499000 Aluminum Cylinder Head - Removal From Engine Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures > Page 3049 WARNING ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH EXTREME CARE. AFTER REMOVING THE HEAD BOLTS, WITHDRAW THE HEAD FROM THE ENGINE COMPARTMENT. USE EXTREME CARE NOTING THAT THE GASKET SURFACE OF THE HEAD COULD BE DAMAGED ON THE WAY OUT OF THE VEHICLE IF ALLOWED TO HIT AGAINST OTHER ENGINE COMPONENTS. ONCE REMOVED, PLACE THE HEAD ON A BENCH, GASKET SIDE UP, USING A PIECE OF CLEAN CARDBOARD ON THE BENCH SURFACE UNDERNEATH. DO NOT SLIDE THE HEAD GASKET SURFACE ALONG THE BENCHTOP OR DAMAGE WILL OCCUR. NOTE SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD BOLTS. CONSULT WITH THE APPROPRIATE MODEL YEAR WORKSHOP MANUAL FIRST, AS THIS PROCEDURE IS USUALLY DONE ON FOUR-VALVE ENGINES. HOWEVER, ALL ALUMINUM HEADS ARE PRONE TO WARPAGE DURING REMOVAL IF TAKEN OFF WHEN HOT OR WARM. THE ENGINE SHOULD BE COOLED SUFFICIENTLY BY THE TIME THE HEADS ARE ACCESSIBLE DURING TEARDOWN. ALLOW AN ADEQUATE COOL DOWN PERIOD. NOTE IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF THE HEAD BOLTS TOGETHER DUE TO TIGHT CLEARANCES OF THE HEAD NEAR HEATER/AC PLENUMS AND THE BODY COWL. THIS WILL ALLOW THE BOLTS TO CLEAR THE BLOCK DECK AS THE HEAD IS WITHDRAWN FROM THE VEHICLE. Place CLEAN shop towels over the cylinder block bores to prevent further contamination from reaching internal parts and surfaces. If a towel is to be removed, do it SLOWLY . Debris collected on the towel can fall on the engine if care is not exercised as it is removed. Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other impressions may allow oil, coolant, and compression gases to leak into other sealed cavities and/or the atmosphere. Surface imperfections deteriorate the head gasket's ability to seal effectively. Contamination on these surfaces will cause leaks from "shimming" the head even under full head bolt torque. Contamination will also cause marks on the polished gasket surface, creating a leak path. Inspection For Damage and Cleaning Procedure The overall straightness of the cylinder head and block face is held within very tight specification. Defects known as "waviness" or "depressions" cannot be surface machined out with ordinary equipment. Machining must meet manufacturer's specification on surface finish quality and be less than 0.001" inch (0.025 mm) level as measured under a known quality straightedge using a feeler gauge. If the engine has been overheated the cylinder head may have been damaged or warped. Re-surfacing will not correct this damage. The head must not contain any impressions on its sealing surface deeper than 0.001" (0.025 mm). There must not be any scratches or gouges present, especially those which track to another sealing cavity or to the atmosphere. Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion, and fluids. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA or equivalent, to rid the surface of any material, which could later interfere with the gasket's sealing ability. WARNING UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED USING RAZOR BLADES, ROTARY ABRASIVE DEVICES INCLUDING ROLOC AND 3M BRANDED SCOTCHBRITE PRODUCTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE BRUSHES, HAND ABRASIVE SUCH AS SANDPAPER OR EMERY CLOTH, OR ANY CARBON STEEL BLADE. THESE TOOLS ARE PROVEN TO CUT AND DAMAGE ALUMINUM AND WILL DISRUPT THE POLISHED FINISH. ABRASIVE PARTICLES ARE ALSO SUSCEPTIBLE TO ENTERING THE ENGINE CAVITIES AND MAY CAUSE INTERNAL ENGINE DAMAGE. THE ONLY TOOLS ACCEPTABLE ARE PLASTIC AND WOOD SCRAPERS COMBINED WITH USE OF MOTORCRAFT METAL SURFACE CLEANER, F4AZ-19A536-RA, OR EQUIVALENT SOLVENT. The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head gasket repair. Use of old bolts can cause clamp load failure because they were stretched from the last torquing procedure either from the plant or a previous field repair. The new head bolt shanks and threads should be thoroughly cleaned, dried, and lightly lubricated. Oil the bolts and let oil drip for a minimum of 5 minutes. Use of too much oil may cause hydraulic lockup in the bolt hole. The corresponding bolt holes in the cylinder block must be free of contamination consisting of dirt particles, coolant, and oil. Bolts can mechanically or hydraulically lock on top of these materials and cause for poor clamping of the cylinder head gasket. Use very lightly compressed air to blow out the bolt holes. Use care to prevent debris from scattering over the internal engine surfaces. To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent can be used with a portable shop vacuum. Move the scraper toward the vacuum nozzle to direct loosened material quickly away from the block surface. It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has been in service. Sanding, scraping, or polishing will create surface depressions that cause leaks. The surface is expected to be flat within 0.001" (0.025 mm) and free of dirt, metal chips, and liquid contaminants. Any staining of the metal surface is considered normal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures > Page 3050 Machining of aluminum heads and blocks is an unacceptable field practice for quality control purposes of flatness and surface finish standards. Removing material will also raise the risk of internal reciprocating components striking each other, as well as changing the emissions calibration of the engine. Machining practices of aluminum blocks and heads are not reimbursable. Ford Remanufacturers are authorized to perform this procedure and have the necessary equipment to put the specified surface finish on the head within original factory limits. Installation Onto the Cylinder Block Surface WARNING ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION CEMENT, COPPER SPRAYS, OR GLUES ARE NOT TO BE USED. THE GASKET MUST BE FITTED DRY WITHOUT SUPPLEMENTAL SEALING AIDS. ATTEMPTS TO SEAL WITH THESE COMPOUNDS WILL CAUSE HEAD SHIMMING AND/OR NEW LEAK PATHS. THESE COMPOUNDS HAVE ALSO BEEN KNOWN TO CAUSE EMISSIONS SENSORS TO FAIL THEREBY TRIPPING FAULT CODES IN THE PCM. Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or liquid contamination and have been prepared for assembly using Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent. Also ensure that any residual dirt on the engine was removed successfully from the surrounding areas of the block to head face of the head and the block. Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the gasket surfaces to scrape or bang against other engine parts. The head may pick up material along the way, if this is allowed. Once in place, with dowels properly aligned to the head and ensuring that the head is fully square, seated, and resting on the block deck in a level condition, install new "torque-to-yield" cylinder head bolts to a finger tight condition. Refer to the appropriate model year Workshop Manual for the procedure to torque the head bolts in the correct sequence and at the intervals specified. Failure to follow these instructions may result in a warped head, and damaged head bolt threads. Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench. Pull evenly and steady on each bolt. Do not exert side pressures on the bolt hex, which can disrupt the integrity of the bolt head and give a false reading on the final torque value of the fastener. Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for the operation. When the engine is ready for starting, ensure that the engine 6i1 pump is (was) primed properly and is in a "ready to start" condition with all engine oil galleys having been charged with oil. WARNING DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL PRESSURE. USE OF A MECHANICAL PRESSURE GAUGE WILL ENSURE THAT OIL FLOW HAS DEVELOPED ON THE PUMP'S PRESSURE SIDE. A DEFECTIVE GAUGE OR LIGHT IN THE INSTRUMENT PANEL WILL NOT VERIFY PRESSURE HAS BEEN OBTAINED. SEVERE INTERNAL ENGINE DAMAGE WILL RESULT IF PRESSURE IS NOT OBSERVED AND STEADILY MAINTAINED. Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks around the gasket joints of the head, front cover, and associated component parts. The vehicle should be road tested within normal guidelines to raise the engine to operating temperature and verify the repair is sound. Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to levels. Check fluid levels using owner guide recommendations (dipstick, sight gages, etc.). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification Cylinder Head Gasket: All Technical Service Bulletins Engine - Reman Engine Head Gasket Identification TSB 06-18-16 09/18/06 IDENTIFYING THE CORRECT REPLACEMENT HEAD GASKET FOR CERTAIN REMANUFACTURED ENGINES - SERVICE TIP FORD: 1999-2006 Mustang, Mustang, Mustang, Mustang, Mustang, Mustang 2000-2005 Thunderbird 2001-2005 Taurus 2001-2006 Crown Victoria, Crown Victoria 2005 Five Hundred, Freestyle 1997-2005 Expedition 1997-2006 E-Series, Explorer, F-150, F-Super Duty 1999-2003 Windstar 1999-2004 F-53 Motorhome Chassis 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape, Escape, Explorer Sport Trac, Ranger 2004-2005 Freestar, Freestar 2006 F-53 Motorhome Chassis LINCOLN: 2000-2006 Lincoln LS 2001-2002 Continental 2001-200 Town Car 1998-2004 Navigator, Navigator 2003-2004 Aviator 2006 Mark LT MERCURY: 2001 Cougar 2001-2005 Sable 2001-2006 Grand Marquis 2003-2006 Marauder 2005 Montego 1997-2006 Mountaineer 2004-2005 Monterey 2005 Mariner ISSUE On various vehicles when servicing the head gasket on certain Ford remanufactured engines, it is critical to determine the type of remanufactured engine that is being serviced, in order to identify the correct replacement gasket. ACTION Follow the Service Procedure to help identify if the vehicle is equipped with a SID (for originally equipment level thickness head gasket) or OVR (for oversized service level thicker head gasket) remanufactured engine when replacing a head gasket. SERVICE PROCEDURE Use this TSB to help identify if the vehicle is equipped with a STD or OVR remanufactured engine when replacing a head gasket. This will ensure that you obtain the proper head gasket (thicker for OVR-oversized) for the engine you are repairing, as the engine may have milled engine block deck, milled cylinder head deck, or an over sized bore in the cylinders. This information will be needed when ordering parts. The parts catalogs already reflect the correct service numbers, as long as this additional information is available. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification > Page 3056 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification > Page 3057 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification > Page 3058 For certain remanufactured engines, the long block assembly will be uniquely identified with a build date, reman code, service part number, and serial number. This metal tag will be marked with STD, or with OVR (Figures 1-6). WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures Technical Service Bulletin # 02-1-4 Date: 020121 Engine Head Gasket - Approved Replacement Procedures Article No. 02-1-4 01/21/02 ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES FORD: 1992-1997 THUNDERBIRD 1992-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 2000-2002 FOCUS 1995-2002 WINDSTAR 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1992-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1992-1997 COUGAR 1992-1999 TRACER 1992-2002 GRAND MARQUIS, SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER ISSUE Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or scratches and dents at the head to block mating surfaces. ACTION Refer to the following Service Information for recommended gasket sealing surface preparation procedures. If the engine diagnosis points to a faulty head gasket (leaks oil, leaks coolant, oil or coolant contamination, or air in coolant), thorough cleaning procedures are necessary for a successful head gasket repair. Diagnosis and post-repair confirmation can be done successfully utilizing leak detection methods such as a black light dye process. SERVICE PROCEDURE To sum up, a successful leak repair depends on: ^ Accurate diagnosis of the leak using Ford-recommended test equipment and procedures ^ Surface preparation and gasket installation using the approved tools, cleaners, and methods ^ Exercising CARE and CLEANLINESS during disassembly/assembly of components ^ Use of genuine Ford OEM replacement parts ^ Use of a Ford Remanufacturer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 499000 Aluminum Cylinder Head - Removal From Engine Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures > Page 3063 WARNING ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH EXTREME CARE. AFTER REMOVING THE HEAD BOLTS, WITHDRAW THE HEAD FROM THE ENGINE COMPARTMENT. USE EXTREME CARE NOTING THAT THE GASKET SURFACE OF THE HEAD COULD BE DAMAGED ON THE WAY OUT OF THE VEHICLE IF ALLOWED TO HIT AGAINST OTHER ENGINE COMPONENTS. ONCE REMOVED, PLACE THE HEAD ON A BENCH, GASKET SIDE UP, USING A PIECE OF CLEAN CARDBOARD ON THE BENCH SURFACE UNDERNEATH. DO NOT SLIDE THE HEAD GASKET SURFACE ALONG THE BENCHTOP OR DAMAGE WILL OCCUR. NOTE SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD BOLTS. CONSULT WITH THE APPROPRIATE MODEL YEAR WORKSHOP MANUAL FIRST, AS THIS PROCEDURE IS USUALLY DONE ON FOUR-VALVE ENGINES. HOWEVER, ALL ALUMINUM HEADS ARE PRONE TO WARPAGE DURING REMOVAL IF TAKEN OFF WHEN HOT OR WARM. THE ENGINE SHOULD BE COOLED SUFFICIENTLY BY THE TIME THE HEADS ARE ACCESSIBLE DURING TEARDOWN. ALLOW AN ADEQUATE COOL DOWN PERIOD. NOTE IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF THE HEAD BOLTS TOGETHER DUE TO TIGHT CLEARANCES OF THE HEAD NEAR HEATER/AC PLENUMS AND THE BODY COWL. THIS WILL ALLOW THE BOLTS TO CLEAR THE BLOCK DECK AS THE HEAD IS WITHDRAWN FROM THE VEHICLE. Place CLEAN shop towels over the cylinder block bores to prevent further contamination from reaching internal parts and surfaces. If a towel is to be removed, do it SLOWLY . Debris collected on the towel can fall on the engine if care is not exercised as it is removed. Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other impressions may allow oil, coolant, and compression gases to leak into other sealed cavities and/or the atmosphere. Surface imperfections deteriorate the head gasket's ability to seal effectively. Contamination on these surfaces will cause leaks from "shimming" the head even under full head bolt torque. Contamination will also cause marks on the polished gasket surface, creating a leak path. Inspection For Damage and Cleaning Procedure The overall straightness of the cylinder head and block face is held within very tight specification. Defects known as "waviness" or "depressions" cannot be surface machined out with ordinary equipment. Machining must meet manufacturer's specification on surface finish quality and be less than 0.001" inch (0.025 mm) level as measured under a known quality straightedge using a feeler gauge. If the engine has been overheated the cylinder head may have been damaged or warped. Re-surfacing will not correct this damage. The head must not contain any impressions on its sealing surface deeper than 0.001" (0.025 mm). There must not be any scratches or gouges present, especially those which track to another sealing cavity or to the atmosphere. Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion, and fluids. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA or equivalent, to rid the surface of any material, which could later interfere with the gasket's sealing ability. WARNING UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED USING RAZOR BLADES, ROTARY ABRASIVE DEVICES INCLUDING ROLOC AND 3M BRANDED SCOTCHBRITE PRODUCTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE BRUSHES, HAND ABRASIVE SUCH AS SANDPAPER OR EMERY CLOTH, OR ANY CARBON STEEL BLADE. THESE TOOLS ARE PROVEN TO CUT AND DAMAGE ALUMINUM AND WILL DISRUPT THE POLISHED FINISH. ABRASIVE PARTICLES ARE ALSO SUSCEPTIBLE TO ENTERING THE ENGINE CAVITIES AND MAY CAUSE INTERNAL ENGINE DAMAGE. THE ONLY TOOLS ACCEPTABLE ARE PLASTIC AND WOOD SCRAPERS COMBINED WITH USE OF MOTORCRAFT METAL SURFACE CLEANER, F4AZ-19A536-RA, OR EQUIVALENT SOLVENT. The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head gasket repair. Use of old bolts can cause clamp load failure because they were stretched from the last torquing procedure either from the plant or a previous field repair. The new head bolt shanks and threads should be thoroughly cleaned, dried, and lightly lubricated. Oil the bolts and let oil drip for a minimum of 5 minutes. Use of too much oil may cause hydraulic lockup in the bolt hole. The corresponding bolt holes in the cylinder block must be free of contamination consisting of dirt particles, coolant, and oil. Bolts can mechanically or hydraulically lock on top of these materials and cause for poor clamping of the cylinder head gasket. Use very lightly compressed air to blow out the bolt holes. Use care to prevent debris from scattering over the internal engine surfaces. To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent can be used with a portable shop vacuum. Move the scraper toward the vacuum nozzle to direct loosened material quickly away from the block surface. It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has been in service. Sanding, scraping, or polishing will create surface depressions that cause leaks. The surface is expected to be flat within 0.001" (0.025 mm) and free of dirt, metal chips, and liquid contaminants. Any staining of the metal surface is considered normal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures > Page 3064 Machining of aluminum heads and blocks is an unacceptable field practice for quality control purposes of flatness and surface finish standards. Removing material will also raise the risk of internal reciprocating components striking each other, as well as changing the emissions calibration of the engine. Machining practices of aluminum blocks and heads are not reimbursable. Ford Remanufacturers are authorized to perform this procedure and have the necessary equipment to put the specified surface finish on the head within original factory limits. Installation Onto the Cylinder Block Surface WARNING ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION CEMENT, COPPER SPRAYS, OR GLUES ARE NOT TO BE USED. THE GASKET MUST BE FITTED DRY WITHOUT SUPPLEMENTAL SEALING AIDS. ATTEMPTS TO SEAL WITH THESE COMPOUNDS WILL CAUSE HEAD SHIMMING AND/OR NEW LEAK PATHS. THESE COMPOUNDS HAVE ALSO BEEN KNOWN TO CAUSE EMISSIONS SENSORS TO FAIL THEREBY TRIPPING FAULT CODES IN THE PCM. Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or liquid contamination and have been prepared for assembly using Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent. Also ensure that any residual dirt on the engine was removed successfully from the surrounding areas of the block to head face of the head and the block. Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the gasket surfaces to scrape or bang against other engine parts. The head may pick up material along the way, if this is allowed. Once in place, with dowels properly aligned to the head and ensuring that the head is fully square, seated, and resting on the block deck in a level condition, install new "torque-to-yield" cylinder head bolts to a finger tight condition. Refer to the appropriate model year Workshop Manual for the procedure to torque the head bolts in the correct sequence and at the intervals specified. Failure to follow these instructions may result in a warped head, and damaged head bolt threads. Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench. Pull evenly and steady on each bolt. Do not exert side pressures on the bolt hex, which can disrupt the integrity of the bolt head and give a false reading on the final torque value of the fastener. Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for the operation. When the engine is ready for starting, ensure that the engine 6i1 pump is (was) primed properly and is in a "ready to start" condition with all engine oil galleys having been charged with oil. WARNING DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL PRESSURE. USE OF A MECHANICAL PRESSURE GAUGE WILL ENSURE THAT OIL FLOW HAS DEVELOPED ON THE PUMP'S PRESSURE SIDE. A DEFECTIVE GAUGE OR LIGHT IN THE INSTRUMENT PANEL WILL NOT VERIFY PRESSURE HAS BEEN OBTAINED. SEVERE INTERNAL ENGINE DAMAGE WILL RESULT IF PRESSURE IS NOT OBSERVED AND STEADILY MAINTAINED. Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks around the gasket joints of the head, front cover, and associated component parts. The vehicle should be road tested within normal guidelines to raise the engine to operating temperature and verify the repair is sound. Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to levels. Check fluid levels using owner guide recommendations (dipstick, sight gages, etc.). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Specifications Front Crankshaft Seal: Specifications Special Tools Removal 1. Remove the crankshaft pulley. 2. Use the (A) Front Cover Seal Remover to remove the (B) front cover seal. Installation 1. Lubricate the (A) and the (B) front oil seal inner lip. Use Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Specifications > Page 3068 2. Use the (A) Crankshaft Seal Replacer/Cover Aligner to install the (B) front cover seal into the (C) engine front cover. 3. Install the crankshaft pulley. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00-18-3 > Sep > 00 > Cooling System - Intake Manifold Gasket Leak Intake Manifold Gasket: All Technical Service Bulletins Cooling System - Intake Manifold Gasket Leak Article No. 00-18-3 09/04/00 ^ COOLING SYSTEM - COOLANT LEAK FROM PASSENGER SIDE OF INTAKE MANIFOLD AT REAR CORNER OF HEAD - VEHICLES BUILT FROM 7/1/1998 THROUGH 6/30/2000 VEHICLES WITH 4.6L 2V OR 5.4L 2V ENGINE ^ ENGINE - 4.6L 2V OR 5.4L 2V-COOLANT LEAK FROM PASSENGER SIDE OF INTAKE MANIFOLD AT REAR CORNER OF HEAD - VEHICLES BUILT FROM 7/1/1998 THROUGH 6/30/2000 FORD: 1999-2000 MUSTANG 2000 ECONOLINE, EXCURSION, EXPEDITION, F-150, SUPER DUTY F SERIES ISSUE The intake manifold may leak or weep coolant from passenger side gasket at right rear corner of head-to-manifold joint. ACTION A new unique passenger side intake manifold gasket has been developed for service and will be available in production later in 2000. This gasket is not to be used on the driver's side. When ordering parts, continue using the existing left side gasket and use the revised gasket for the right side. Refer to the applicable Workshop Manual, Section 303-01 under heading "Intake Manifold Removal, In-Vehicle Service" for procedure details. NOTE: TAKE EXTREME CAUTION NOT TO ALLOW FOREIGN MATERIAL TO ENTER INTAKE PASSAGES WHILE MANIFOLD IS REMOVED. USE TAPE TO COVER INTAKE PORTS IN HEAD WHILE MANIFOLD IS REMOVED FOR GASKET SERVICE. Parts Information OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000, 404000, 499000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 00-18-3 > Sep > 00 > Cooling System - Intake Manifold Gasket Leak Intake Manifold Gasket: Customer Interest Cooling System - Intake Manifold Gasket Leak Article No. 00-18-3 09/04/00 ^ COOLING SYSTEM - COOLANT LEAK FROM PASSENGER SIDE OF INTAKE MANIFOLD AT REAR CORNER OF HEAD - VEHICLES BUILT FROM 7/1/1998 THROUGH 6/30/2000 VEHICLES WITH 4.6L 2V OR 5.4L 2V ENGINE ^ ENGINE - 4.6L 2V OR 5.4L 2V-COOLANT LEAK FROM PASSENGER SIDE OF INTAKE MANIFOLD AT REAR CORNER OF HEAD - VEHICLES BUILT FROM 7/1/1998 THROUGH 6/30/2000 FORD: 1999-2000 MUSTANG 2000 ECONOLINE, EXCURSION, EXPEDITION, F-150, SUPER DUTY F SERIES ISSUE The intake manifold may leak or weep coolant from passenger side gasket at right rear corner of head-to-manifold joint. ACTION A new unique passenger side intake manifold gasket has been developed for service and will be available in production later in 2000. This gasket is not to be used on the driver's side. When ordering parts, continue using the existing left side gasket and use the revised gasket for the right side. Refer to the applicable Workshop Manual, Section 303-01 under heading "Intake Manifold Removal, In-Vehicle Service" for procedure details. NOTE: TAKE EXTREME CAUTION NOT TO ALLOW FOREIGN MATERIAL TO ENTER INTAKE PASSAGES WHILE MANIFOLD IS REMOVED. USE TAPE TO COVER INTAKE PORTS IN HEAD WHILE MANIFOLD IS REMOVED FOR GASKET SERVICE. Parts Information OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000, 404000, 499000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair Special Tools Removal 1. Remove the valve springs. 2. Remove the valve stem seals. Installation 1. Note: The valve stem seal must be bottomed on the valve seat. Note: Make sure that the garter spring is present in the valve stem seal. Use the (A) Valve Stem Seal Replacer to install the (B) valve stem seals. 2. Install the valve springs. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Sender: Customer Interest Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 3094 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Sender: All Technical Service Bulletins Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 3100 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Specifications Oil Pressure Sensor: Specifications Oil Pressure sensor 107 - 142 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft sprocket bolts refer to the procedure in this section Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams > Windsor Engine Timing Chain: Diagrams Windsor Engine CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur. Position the crankshaft with the keyway at the 12 o'clock position. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks. - LH camshaft timing mark is approximately at 12 o'clock. - RH camshaft timing mark is approximately at 11 o'clock. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams > Windsor Engine > Page 3112 Fig. 26 Crankshaft Sprocket Position NOTE: Crankshaft sprockets are identical. They may only be installed one way. Refer to the following for correct crankshaft sprocket installation. - Install the LH timing chain onto the crankshaft sprocket, aligning the one copper link on the timing chain with the slot on the crankshaft sprocket. - Position the timing chain on the camshaft sprocket with the two copper chain links and the camshaft sprocket timing mark aligned. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams > Windsor Engine > Page 3113 - NOTE: Be sure the copper chain link and crankshaft sprocket timing mark are aligned. - Position the outer camshaft sprocket and the RH timing chain with the long hub of the sprocket facing inward. - Position the RH timing chain on the camshaft sprocket. Make sure the two copper-colored links align with the camshaft sprocket timing mark. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams > Windsor Engine > Page 3114 Timing Chain: Diagrams Romeo Engine Both camshaft keyways are 90 degrees from the valve cover surface. Make sure the copper links line up with the dots on the camshaft sprocket. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks. Fig. 26 Crankshaft Sprocket Position - NOTE: Crankshaft sprockets are identical. They may only be installed one way. Refer to the following illustration for correct crankshaft sprocket installation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams > Windsor Engine > Page 3115 - Install the LH (inner) timing chain on the crankshaft sprocket, aligning the copper link with the dot on the crankshaft sprocket. - Install the LH (inner) timing chain on the camshaft sprocket, aligning the copper link with the dot on the camshaft sprocket. - Install the RH (outer) timing chain on the crankshaft sprocket, aligning the copper link with the dot on the crankshaft sprocket. - Install the RH (outer) timing chain on the camshaft sprocket, aligning the copper link with the dot on the camshaft sprocket. - Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Windsor Engine Timing Chain: Service and Repair Windsor Engine Special Service Tool(s) Removal CAUTION: Since the engine is not free-wheeling, if the crankshaft or the camshafts are moved in any manner during removal and installation the crankshaft and camshafts must be re-synchronized. These steps are located in Engine Assembly Steps 35 to 48. 1. Remove the engine front cover. 2. Remove the crankshaft sensor ring from the crankshaft. 3. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Windsor Engine > Page 3118 Position the crankshaft with the keyway at the 12 o'clock position. 4. Install and fully tighten the Camshaft Holding Tools on both camshafts. 5. Remove the timing chain tensioning system from both timing chains. 1 Remove the bolts. 2 Remove the timing chain tensioners. 3 Remove the timing chain tensioner arms. 6. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinders heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur. Remove the LH and RH timing chains and the crankshaft sprockets. Remove the RH timing chain from the camshaft sprocket. - Remove the RH timing chain and outer crankshaft sprocket from the crankshaft. - Repeat for the LH timing chain and crankshaft sprocket. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Windsor Engine > Page 3119 7. Remove both timing chain guides. - Remove the bolts. - Remove both timing chain guides. Installation 1. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly. Compress the tensioner plunger, using an edge of a vise. 2. Using a small screwdriver or pick, push back and hold the ratchet mechanism. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Windsor Engine > Page 3120 3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing. 4. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation. 5. Remove the tensioner from the vise. 6. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Windsor Engine > Page 3121 7. Install the timing chain guides. 8. CAUTION: Do not turn the engine over with the camshaft positioning tool or damage to the camshaft sprocket or the bolt may occur. Use the Camshaft Positioning Tool to position the camshaft. 9. Slightly loosen the camshaft holding tools to allow slight camshaft movement. Rotate the LH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 12 o'clock. Rotate the RH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 11 o'clock. Tighten the Camshaft Holding Tools to maintain camshaft pre-positioning. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Windsor Engine > Page 3122 10. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur. CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and/or valve damage can occur. Position the crankshaft with the Crankshaft Holding Tool. 11. Remove the Crankshaft Holding Tool. Fig. 26 Crankshaft Sprocket Position 12. NOTE: Crankshaft sprockets are identical. They may only be installed one way. Refer to the following illustration for correct crankshaft sprocket installation. If removed, install the LH and RH crankshaft sprockets. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Windsor Engine > Page 3123 13. Install the LH timing chain onto the crankshaft sprocket, aligning the one copper link on the timing chain with the slot on the crankshaft sprocket. 14. Note: Make sure the upper half of the timing chain is below the tensioner guide dowel. If necessary, use the Camshaft Positioning Tool to adjust. Note: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment Position the timing chain on the camshaft sprocket with the two copper chain links and the camshaft sprocket timing mark aligned. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Windsor Engine > Page 3124 15. CAUTION: The camshaft sprocket can jump if the Camshaft Holding Tool is not secured. Note: Be sure the copper chain link and crankshaft sprocket timing mark are aligned. Note: The lower half of the timing chain must be positioned above the dowel. Position the outer camshaft sprocket and the RH timing chain with the long hub of the sprocket facing inward. 16. Note: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment with the Camshaft Positioning Tool. Position the RH timing chain on the camshaft sprocket. Make sure the two copper-colored links align with the camshaft sprocket timing mark. 17. Position the LH and RH timing chain tensioner arms on the dowel pins. Position the timing chain tensioner assemblies, and install the timing bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Windsor Engine > Page 3125 18. Remove the RH and LH pins form the timing chain tensioner assembly. 19. Remove the Camshaft Holding Tool. 20. As a post-check, verify correct alignment of all timing marks. 21. Position the crankshaft sensor ring on the crankshaft. 22. Apply a bead of silicone along the head-to-block surface and the oil pan-to-block surface as specified. - Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. 23. Install the engine front cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Windsor Engine > Page 3126 Timing Chain: Service and Repair Romeo Engine Timing Drive Components Special Tool(s) Removal CAUTION: Since the engine is not free-wheeling, timing procedures must be followed exactly or piston and valve damage may occur. 1. Remove the engine front cover. 2. Remove the crankshaft sensor ring from the crankshaft. 3. Rotate the crankshaft until both camshaft keyways are 90 degrees from the valve cover surface. Make sure the copper links line up with the dots on the camshaft sprocket. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Windsor Engine > Page 3127 4. Install the special tools on the camshaft. add image 5. Remove the timing chain tensioning system from both timing chains. 1. Remove the bolts. 2. Remove the timing chain tensioners. 3. Remove the timing chain tensioner arms. 6. Remove the timing chains and crankshaft sprockets. 7. Remove the timing chain guides. 1. Remove the bolts. 2. Remove the LH timing chain guide. 3. Remove the bolts. 4. Remove the RH timing chain guide. Installation 1. CAUTION: Timing and procedures must be followed exactly or damage to valves and pistons will result. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly. Compress the tensioner plunger, using an edge of a vise. 2. Using a small screwdriver or pick, push back and hold the ratchet mechanism. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Windsor Engine > Page 3128 3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing. 4. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation. 5. Remove the tensioner from the vise. 6. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Windsor Engine > Page 3129 7. Install the timing chain guide. 1. Position LH timing chain guide. 2. Install and tighten the bolts. 3. Position the RH timing chain guide. 4. Install and tighten the RH bolts. 8. NOTE: Crankshaft sprockets are identical. They may only be installed one way. Refer to the following illustration for correct crankshaft sprocket installation. If removed, install the LH and RH crankshaft sprocketsts add image 9. CAUTION: Unless otherwise instructed, do not rotate either the crankshaft or the camshafts, when the timing chains are removed and the cylinder heads are installed. Severe piston and valve damage will occur. NOTE: The number one cylinder is at Top Dead Center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool. Using the special tool, position the crankshaft so the number one cylinder is at TDC. 10. Remove the special tool. 11. Install the timing chains. ^ Install the LH (inner) timing chain on the crankshaft sprocket, aligning the copper link with the dot on the crankshaft sprocket. ^ Install the LH (inner) timing chain on the camshaft sprocket, aligning the copper link with the dot on the camshaft sprocket. ^ Install the RH (outer) timing chain on the crankshaft sprocket, aligning the copper link with the dot on the crankshaft sprocket. ^ Install the RH (outer) timing chain on the camshaft sprocket, aligning the copper link with the dot on the camshaft sprocket. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Windsor Engine > Page 3130 12. Position the LH and RH timing chain tensioner arm on the dowel pins. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Windsor Engine > Page 3131 13. Position the RH timing chain tensioner and install the bolts. 14. Position the LH timing chain tensioner and install the bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Windsor Engine > Page 3132 15. Remove both the RH and LH retaining pins from the timing chain tensioner. add image 16. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket 17. Remove special tools from the camshaft. 18. Install the crankshaft sensor ring on the crankshaft. 19. Install the engine front cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications Timing Chain Guide: Specifications Timing chain guide bolts 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Timing chain hydraulic tensioner bolts 15 - 22 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine front cover bolts (1-7) 15 - 22 ft.lb Engine front cover bolts (6-15) 30 - 40 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3142 Timing Cover: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove both of the valve covers. 3. Remove the radiator. 4. Remove the water pump. 5. Raise and support the vehicle. 6. Remove the top bolts and the lower bolt and position the power steering pump aside. 7. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 8. Remove the drain plug and drain the engine oil. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3143 9. Remove the front bolts. 10. Remove the crankshaft front seal. 11. Lower the vehicle. 12. Disconnect the Camshaft Position (CMP) sensor electrical connection. 13. Remove the (A) bolt and the (B) belt idler pulley. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3144 14. Remove the bolts. 15. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Remove the engine front cover from the front cover to cylinder block dowel. Remove the engine front cover gasket and clean and inspect the mating surfaces. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Note: If the engine front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or four Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3145 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Note: Make sure that the engine front cover gasket is in place on the engine front cover before installation. Apply the silicone along the cylinder head to cylinder block surface and the oil pan to cylinder block surface. Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4. 2. Install the engine front cover with engine front cover gasket on the front cover to cylinder block dowel and loosely install the bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3146 3. Tighten the engine front cover fasteners in sequence in two stages. - Stage 1: Tighten fasteners 1 through 7 to 20 - 30 Nm (15 - 22 ft. lbs.). - Stage 2: Tighten fasteners 6 through 15 to 40 - 55 Nm (30 - 41 ft. lbs.). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3147 4. Position the (A) belt idler pulley and install the (B) bolt. 5. Connect the CMP electrical connection. 6. Raise and support the vehicle. 7. Install a new crankshaft front oil seal. 8. Loosely install the bolts, then tighten the bolts in the two stages following the sequence shown. - Stage 1: Tighten to 20 Nm (15 ft. lbs.). - Stage 2: Tighten an additional 60 degrees. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3148 9. Connect the crankshaft position sensor electrical connector. 10. Note: The front lower hole in the power steering pump is not used. Position the power steering pump and install the bolts. 11. Install the drain plug. 12. Lower the vehicle. 13. Install the valve covers. 14. Fill the engine with oil. - Use Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 15. Install the water pump. 16. Install the radiator. 17. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve 7.75 Nm Fuel Pressure Relief Valve Cap 0.6 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3154 Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 700 - 760 RPM Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Locations > Page 3162 Air Filter Element: Service Precautions CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Locations > Page 3163 Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet Air Cleaner (ACL) aside. 2. Remove the (A) Air Cleaner (ACL) element from the (B) open end of the inlet air cleaner. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure the tabs are aligned properly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD . Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3168 Fuel Pressure Release: Service and Repair SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. ^ This will drain some fuel out of the system. Place the fuel in a suitable container. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3169 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications V8 Firing Order: 1 3 7 2 6 5 4 8 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 3173 Firing Order: Locations V8 Firing Order: 1 3 7 2 6 5 4 8 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plugs 9-20 Nm Original Spark Plug AWSF22E Replacement Spark Plug AWSF22E Spark Plug Gap 1.32-1.42 mm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 3182 Spark Plug: Specifications Spark Plugs 9-20 Nm Original Spark Plug AWSF22E Replacement Spark Plug AWSF22E Spark Plug Gap 1.32-1.42 mm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3183 Spark Plug: Application and ID Original Spark Plug Type ..................................................................................................................... ............................................................... AWSF22E Replacement Spark Plug Type .......................... ................................................................................................................................................... AWSF22E Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3184 Spark Plug: Description and Operation The spark plugs: ^ change a high voltage pulse into a spark which ignites the fuel and air mixture. ^ originally equipped on the vehicle have a platinum-enhanced electrode for long life. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal and Installation Spark Plug: Service and Repair Removal and Installation SPARK PLUG Engine Ignition - RH Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal and Installation > Page 3187 Engine Ignition - LH Exploded View Material Removal and Installation See TSB 8-1-9 Jan. 2008 1. Disconnect the ignition coil electrical connector. 2. NOTE: When removing the ignition coils, a slight twisting motion will break the seal and ease removal. Remove the bolt and the ignition coil. 3. NOTICE: Do not remove the spark plugs when the engine is hot or cold soaked. Spark plug thread or cylinder head damage can occur. Make sure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal and Installation > Page 3188 the engine is warm (hand touch after cooling down) prior to spark plug removal. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. Remove the spark plug in the following sequence. (1).Loosen the spark plug no more than one-eighth to one-fourth of a turn. (2).NOTICE: Excessive use of carburetor tune-up cleaner can introduce enough liquid volume to hydro-lock the engine. Using carburetor tune-up cleaner, fill the spark plug well until fluid has reached the spark plug jamb nut. Follow the directions on the packaging. (3).NOTICE: Do not loosen or tighten the spark plug for a minimum of 15 minutes or damage to the cylinder head or spark plug may occur. Let the carburetor tune-up cleaner soak for a minimum of 15 minutes. (4).NOTE: Some screeching and high effort may be noticed and is normal. NOTE: The expected removal torque is around 45 Nm (33 lb-ft). Tighten, and then loosen the spark plug, repeating until turning effort is reduced, and remove the spark plug. 4. Inspect the spark plug. Install a new spark plug as necessary. Installation 1. NOTICE: The spark plug gap is NOT adjustable. Damage can occur to the ceramic if the spark plug gap is adjusted. Install a new spark plug if the gap is out of specification. NOTE: Refer to the specifications in this section for correct spark plug identification. NOTE: Do not apply high temperature nickel anti-seize lubricant to the spark plug ground strap area. Apply high temperature nickel anti-seize lubricant to only the spark plug ground electrode shield as shown. 2. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. Install the spark plug. To install, tighten to 34 Nm (25 lb-ft). 3. NOTE: Verify that the ignition coil spring is correctly located inside the ignition coil-on-plug boot and that there is no damage to the tip of the boot. Install the ignition coil and the bolt. Apply a light coat of dielectric compound to the inside of the ignition coil boots. To install, tighten to 6 Nm (53 lb-in). 4. Connect the ignition coil electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal and Installation > Page 3189 Spark Plug: Service and Repair Spark Plug - Inspection REMOVAL 1. Remove the coil on plugs. For additional information refer to Ignition Coil. 2. Remove the spark plugs. NOTE: Remove any foreign material from the spark plug wells with compressed air before removing the spark plugs. 3. Inspect the spark plugs. For additional information, refer to Engine. 4. Adjust the spark plug gap as necessary. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 within 75 percent of the highest reading. For additional information, refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3193 Compression Check: Testing and Inspection General Remarks Note: Removing fuses and disconnecting electrical components causes the Powertrain Control Module (PCM) to log an error message. After the measurements have been carried out this error message should be cleared from memory by connecting to PDU. Note: Only check the compression pressure with the valves set to the prescribed clearance (if this can be adjusted). The compression pressure should be checked with the engine at operating temperature. Check The Compression Pressure WARNING: On manual transmissions shift the transmission into neutral. On automatic transmission vehicles, select "P". Failure to follow these instructions may result in personal injury. 1. Remove the fuel pump relay. 2. Start the engine-the engine will start, run for a few seconds then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter switch in the starting circuit. With the ignition switch OFF, using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 6. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 7. Install the components in reverse order, observing the specified tightening torques. 8. Reset the PCM fault memory. Interpretation of the Results The indicated compression pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading. CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent damage to the catalytic converter. If the measurement on one or more cylinders is much lower than the specified value, spray some engine oil into the combustion chamber and repeat the compression measurement. If the reading greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other arc both too low then it is very likely that the cylinder head gasket between them is burnt through. This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer does not indicate whether this vehicle has adjustable or non-adjustable valves. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Water Pump Water Pump: Specifications Water pump bolts 15 - 22 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Water Pump > Page 3201 Water Pump: Specifications Water pump pulley bolts 15 - 22 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3202 Water Pump: Service and Repair Removal and Installation 1. Remove the engine cooling fan and fan shroud. 2. Remove the drive belt. 3. Remove the water pump pulley. 4. Remove the water pump. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 3208 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Without Rear Aux. Heat 22.6 L With Rear Aux. Heat 24.9 L Without Rear Aux. Heat 24.1 L With Rear Aux. Heat 26.4 L Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 3211 Coolant: Fluid Type Specifications Antifreeze Type Ford Premium Engine Coolant (Green in color) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications Cylinder block drain plug 12 - 18 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Specifications Coolant Line/Hose: Specifications Water outlet connection bolts 18 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications Coolant Reservoir: Specifications Degas bottle bolts ................................................................................................................................ .................................................... 9 Nm (80 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 3221 Coolant Reservoir: Service and Repair Removal and Installation 1. Partially drain the cooling system. 2. Remove the hose from the radiator. 1 Release the hose clamp and slide away from the hose end. 2 Slide the hose off the radiator fitting. 3. Remove the lower radiator hose from the degas bottle. 4. Remove the degas bottle. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications Fan Clutch: Specifications Fan Blade to fan clutch bolts 13 ft.lb Fan blade and fan clutch to water pump pulley 41 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications > Page 3226 Fan Clutch: Tools and Equipment Fan Clutch Holding Tool AST tool# 8005 Allows the technician to hold the water pump pulleuy in place while loosening the radiator fan. 2009 Suggested user price: $41.20 Assenmacher Specialty Tools 1 800 525 2943 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor 20 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder head temperature sensor (CHT) 18 - 20 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 3234 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor Engine Temperature Sensor: Description and Operation CHT Sensor The CHT sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends a signal to the PCM indicating cylinder head temperature. ^ If the temperature exceeds 126°C (258°F) 5.4L, 130°C (265°F) 4.6L, the PCM disables four fuel injectors at a time. The PCM will alternate which four fuel injectors are disabled every 32 engine cycles. The four cylinders the are not being fuel injected act as air pumps to aid in cooling the engine. ^ If the temperature exceeds 154°C (310°F) 5.4L, 166°C (330°F) 4.6L, the PCM disables all of the fuel injectors until the engine temperature drops below 154°C (310°F) 5.4L, 153°C (308°F) 4.6L. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor > Page 3237 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor communicates an overheating condition to the PCM. The PCM would then initiate a cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using a CHT sensor and cooling strategy would prevent damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > Page 3238 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting or jacking an air suspension vehicle.This can be accomplished by turning off the air suspension switch located below the glove box in the lower right of the passenger foot well. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during the operations. Failure to follow the instructions may result in personal injury. Raise the vehicle on a hoist. 2. Remove the right front fender splash shield. 3. Remove the dual converter Y-pipe. 4. Remove the components in the order indicated in the following illustration and table. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Water temperature indicator sender unit 15 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 3242 Temperature Sensor (Gauge): Description and Operation Engine Coolant Temperature Gauge Engine coolant temperature information is received by the instrument cluster from the PCM over the SCP network. Temperatures over 121°C (275°F) will display hot (H). If the engine coolant temperature data is missing or invalid for five seconds, the instrument cluster will move the engine coolant temperature gauge below the cold (C) position. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications Fan Shroud: Specifications Fan shroud bolts 71 - 88 in.lb Fan Shroud screws 80 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3254 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3255 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3261 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3262 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3263 Heater Core: Specifications Junction block bracket screw 12 Nm Starter relay cable nut 8 Nm Starter relay cable ends 8 Nm Heater Core Bracket Screws 1.5 - 2.5 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3264 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3265 Heater Core: Service Precautions WARNING: ^ CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. ^ THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Auxiliary Climate Control Heater Core: Description and Operation Auxiliary Climate Control The auxiliary A/C system uses a rear heater core which operates in the same manner as the front heater core. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Auxiliary Climate Control > Page 3268 Heater Core: Description and Operation Main Climate Control Heater Core The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer the heat to air passing through the plenum. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Page 3269 Heater Core: Testing and Inspection WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require installation of a new heater core. If a heater core leak is suspected, the heater core must be tested by following the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly. 2. Check the integrity of the heater water hose clamps. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Heater Core Plugged WARNING: THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. 1. Check to see that the engine coolant is at the proper level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot: ^ the heater core may have an air pocket. ^ the heater core may be plugged. ^ the thermostat may not be working correctly. Heater Core-Pressure Test Use the radiator/heater core pressure tester to carry out the pressure test. 1. Drain the coolant from the cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the radiator/heater core pressure tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the bench test. 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 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Page 3270 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new the heater core. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Auxiliary Climate Control Heater Core: Service and Repair Auxiliary Climate Control REMOVAL 1. Remove the air conditioning and heater assembly. Refer to: Heating and Air Conditioning, Evaporator Case, Service and Repair, Auxiliary Climate Control, See: Heating and Air Conditioning/Evaporator Case/Service and Repair/Auxiliary Climate Control 2. Remove the evaporator/heater core access cover. 1 Remove the ten bolts. 2 Remove the evaporator/heater core access cover. 3. Remove the heater core. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Auxiliary Climate Control > Page 3273 Heater Core: Service and Repair Main Climate Control REMOVAL NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 1. Disconnect the battery ground cable. 2. Drain the radiator. 3. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Installation 4. Disconnect the heater core hose couplings. 5. Remove the A/C plenum demister adapter. 1 Remove the screw. 2 Remove the A/C plenum demister adapter. 6. Disconnect the vacuum line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Auxiliary Climate Control > Page 3274 7. Remove the heater core bracket. 1 Remove the two screws. 2 Remove the bracket. 8. Remove the plenum chamber top. 1 Remove the 13 screws. 2 Remove the plenum chamber top. 9. Remove the blend door assembly from the case. 10. Remove the heater core. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Auxiliary Climate Control > Page 3275 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3284 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3285 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3291 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3292 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 3293 Heater Hose: Specifications Junction block bracket screw 12 Nm Starter relay cable nut 8 Nm Starter relay cable ends 8 Nm Hose Clamp 1.6 - 2.2 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 3294 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 3295 Heater Hose Coupler Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 3296 Heater Hose: Service Precautions WARNING: THE ENGINE MUST BE OFF, FULLY COOL AND THE COOLING SYSTEM FULLY DEPRESSURIZED BEFORE ATTEMPTING TO DISCONNECT ANY HEATER WATER HOSES. FAILURE TO COMPLY WITH THIS WARNING CAN RESULT IN SERIOUS INJURY OR BURNS FROM HOT LIQUID ESCAPING OUT OF THE ENGINE COOLING SYSTEM. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 3297 Heater Hose: Description and Operation Refrigerant Lines: Part 1 0f 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 3298 Refrigerant Lines: Part 2 Of 2 The auxiliary lines are two-piece tubes that are secured to the underbody of the vehicle. New auxiliary line kits are only available with multiple-piece lines for ease of installation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control Heater Hose: Service and Repair Auxiliary Climate Control Line - Front Auxiliary Heater Outlet and Inlet Refrigerant Lines: Part 1 0f 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3301 Refrigerant Lines: Part 2 Of 2 REMOVAL NOTE: The front auxiliary heater outlet line is shown; the front auxiliary heater inlet line is similar. 1. Drain the cooling system. For additional information, refer to Cooling System. 2. Turn the air suspension switch off, if equipped. 3. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 4. Remove the wheel and tire assembly. For additional information, refer to Wheels,Tires and Alignment. 5. Loosen the RH front fender splash shield. 1 Remove the bolts. 2 Remove the pin-type retainers. 3 Move the front fender splash shield to access the lines. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3302 6. Remove the three line bracket retaining nuts. 7. Remove the three line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 8. Disconnect the heater outlet line from the outlet hose coupling. 9. Disconnect the front auxiliary heater outlet line from the rear auxiliary heater outlet line. 1 Remove the nut. 2 Disconnect the line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3303 10. Cut the heater outlet line where it crosses under the frame. 11. Cut the heater outlet line near the front wheel well opening. 12. Remove and discard the cut sections. INSTALLATIONS NOTE: Refer to the Multiple-Piece Auxiliary A/C Heater Line Kit illustration in Description and Operation. 1. Install the heater outlet line. ^ Install the end with the blue tape over the frame. 2. Connect the heater outlet line peanut fitting. 1 Connect the fitting. 2 Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3304 3. Install the heater outlet line. ^ Install the end with the red tape over the frame. ^ Install the end with the yellow tape between the frame and the body vertical flange. NOTE: View shown with fender skirt removed for clarity. 4. Connect the heater water outlet line to the heater water outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fitting. 2 Loosely install the nut. 5. Install the heater water outlet line to the heater water outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. ^ Install the line through the wheel opening. NOTE: Fender skirt removed for clarity. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3305 6. Connect the heater water outlet line to the heater water outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fitting. 2 Loosely install the nut. 7. Tighten the three peanut fittings. 8. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: ^ Verify that clearance exists between the frame and the lines to prevent component damage. ^ Overtightening of the nut will cause the stud to break away from the floorpan. NOTE: The bracket must be positioned equally between the white location marks on the line. 9. Connect the heater water outlet line to the engine heater outlet hose coupling. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3306 10. Install the bolts, the pin-type retainers and the front fender splash shield. 11. Install the wheel and tire assembly. For additional information, refer to Wheels,Tires and Alignment. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Fill the cooling system. For additional information, refer to Cooling System. Inlet Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3307 Refrigerant Lines: Part 1 0f 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3308 Refrigerant Lines: Part 2 Of 2 REMOVAL 1. Drain the cooling system. For additional information, refer to Cooling System. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater inlet hose coupling. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3309 7. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 8. Lower the muffler heat shield. 1 Remove the two front bolts. 2 Lower the heat shield. 9. Remove the four line bracket retaining nuts. 10. Remove the four line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 11. Disconnect the inlet line peanut fitting. 1 Remove the nut. 2 Disconnect the line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3310 12. Cut the heater inlet line near the A/C line grommet. 13. Cut the heater inlet line near the rear crossmember. 14. Cut the heater inlet line between the frame and the muffler heat shield. 15. Remove and discard the cut sections. INSTALLATION NOTE: ^ Lay out new lines in vehicle position to assist in installation. ^ Refer to the Multiple-Piece Auxiliary A/C Heater Line Kit illustration in Description and Operation. 1. Install the heater inlet line. ^ Starting from the rear of the vehicle, install the end with the green tape over the rear axle between the frame crossmember and the body. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3311 2. Connect the heater inlet line peanut fitting. 1 Connect the inlet lines. 2 Loosely install the nut. 3. Install the heater inlet line. ^ Starting from the rear of the vehicle, install the end with the blue tape between the frame crossmember and the floor pan. 4. Connect the heater inlet line to the heater inlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fittings. 2 Loosely install the nut. 5. Install the heater inlet line. 1 Remove the RH rear wheel and tire. 2 Install the end with the red tape between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3312 6. Connect the heater inlet line to the heater inlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fittings. 2 Loosely install the nut. 7. Install the heater inlet line. ^ Install the end with the green tape through the floor opening. 8. Connect the heater inlet line to the heater inlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fittings. 2 Loosely install the nut. 9. Tighten the four peanut fittings. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3313 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floor pan. NOTE: The bracket must be positioned equally between the white location marks on the line. 11. Install the muffler heat shield. 1 Position the shield. 2 Install the nuts. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 15. Connect the heater inlet hose coupling. 16. Install the quarter trim access panel. 17. Install the spare tire. 18. Fill the cooling system. For additional information, refer to Cooling System. Outlet Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3314 Refrigerant Lines: Part 1 0f 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3315 Refrigerant Lines: Part 2 Of 2 REMOVAL 1. Drain the cooling system. For additional information, refer to Cooling System. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater outlet hose coupling. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3316 7. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 8. Lower the muffler heat shield. 1 Remove the two front bolts. 2 Lower the heat shield. 9. Remove the four line bracket retaining nuts. 10. Remove the four line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 11. Disconnect the outlet line peanut fitting. 1 Remove the nut. 2 Disconnect the line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3317 12. Cut the heater outlet line near the grommet. 13. Cut the heater outlet line near the rear crossmember. 14. Cut the heater outlet line between the frame and the muffler heat shield. 15. Remove and discard the cut sections. INSTALLATION NOTE: ^ Lay out new lines in vehicle position to assist in installation. ^ Refer to the Multiple-Piece Auxiliary A/C Heater Line Kit illustration in Description and Operation. 1. Install the heater outlet line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3318 ^ Starting from the rear of the vehicle, install the end with the blue tape over the axle between the frame and the body. 2. Connect the heater outlet line peanut fitting. 1 Connect the outlet lines. 2 Loosely install the nut. 3. Install the heater outlet line. ^ Starting from the rear of the vehicle, install the end with the red tape between the frame and the floor pan. 4. Connect the heater outlet line to the heater outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fittings. 2 Loosely install the nut. 5. Install the heater outlet line. 1 Remove RH rear wheel and tire. 2 Install the end with blue tape between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3319 6. Connect the heater outlet line to the heater outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fittings. 2 Loosely install the nut. 7. Install the heater outlet line. ^ Install the end with the hose through the floor opening. 8. Connect the heater outlet line to the heater outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fittings. 2 Loosely install the nuts. 9. Tighten the four peanut fittings. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3320 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floorpan. NOTE: The bracket must be positioned equally between the white location marks on the line. 11. Install the muffler heat shield. 1 Position the shield. 2 Install the nuts. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 15. Connect the heater outlet hose coupling. 16. Install the quarter trim access panel. 17. Install the spare tire. 18. Fill the cooling system. For additional information, refer to Cooling System. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3321 Heater Hose: Service and Repair Heater Hose Coupling Disconnect Procedure Heater Hose Disconnect Tool SPECIAL SERVICE TOOL(S) DISCONNECT 1. Depressurize the engine cooling system. WARNING: THE ENGINE MUST BE OFF, FULLY COOL AND THE COOLING SYSTEM FULLY DEPRESSURIZED BEFORE ATTEMPTING TO DISCONNECT ANY HEATER WATER HOSES. FAILURE TO COMPLY WITH THIS WARNING CAN RESULT IN SERIOUS INJURY OR BURNS FROM HOT LIQUID ESCAPING OUT OF THE ENGINE COOLING SYSTEM. 2. Push the heater water hose toward the tube to fully expose the locking tabs. 3. Push the Heater Hose Disconnect Set over the coupling retainer windows to compress the retainer locking tabs. NOTE: When compressing the white coupling retainer, the Heater Hose Disconnect Set must be perpendicular to and on the highest point of the coupling. 4. Pull the heater water hose away from the heater core tube. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to assist in the removal. 5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3322 7. Spread the retainer tabs apart and slide the retainer off the tube. 8. Discard the retainer. CONNECT 1. Clean the tubes and lubricate with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESF-M99B112-A. 2. Install a new coupling retainer, spacer, and lubricated O-rings into the quick disconnect coupling housing. 3. Push the heater water hose with a quick disconnect coupling onto the tube. 4. Make sure the coupling is fully engaged by lightly pulling on the heater water hose. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3323 Heater Hose: Service and Repair Heater Hose Assembly REMOVAL 1. Drain the radiator. For additional information, refer to Cooling System. 2. Disconnect the heater outlet hose at the engine. 3. Disconnect the heater inlet hose at the engine. 1 Loosen the hose clamp. 2 Disconnect the heater inlet hose. 4. Disconnect the heater core hose couplings. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 3324 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Page 3325 Heater Hose Disconnect And Removal Tools Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Customer Interest for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Radiator: Customer Interest A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Customer Interest for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3338 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Customer Interest for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3339 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Customer Interest for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3340 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Radiator: All Technical Service Bulletins A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3346 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3347 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3348 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Page 3349 Radiator: Specifications Radiator support bracket bolts 22 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Page 3350 Radiator: Service and Repair Removal 1. Remove the fan blade. 2. Disconnect the transmission fluid cooler fittings. 1 Disconnect the upper transmission fluid cooler fitting. 2 Disconnect the lower transmission fluid cooler fitting. 3. Disconnect the lower radiator hose from the radiator. 1 Pry the locking tab up and out of the slot. 2 Rotate the lower radiator hose. 3 Disconnect the lower radiator hose. 4. Remove the radiator. 1 Remove the bolts. 2 Remove the upper radiator support brackets and the jack handle and wheel nut wrench retainers. 3 Lift the radiator off the radiator mounting insulators. 4 Remove the radiator mounting insulators. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Page 3351 1. Install the radiator. 1 Install the radiator mounting insulators. 2 Position the radiator on the radiator mounting insulators. 3 Position the brackets and the jack handle and wheel nut wrench retainers. 4 Install the bolts. 2. Connect the lower radiator hose and upper radiator hose. 1 Push the hose onto quick connect fitting. 2 Bend the locking tab into retaining slot. 3. Connect the transmission fluid cooler lines. 1 Connect the lower transmission fluid cooler line. 2 Connect the upper transmission fluid cooler line. 4. Install the fan blade. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications Radiator Cap: Specifications Pressure relief cap opening pressure 16 psi Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor 20 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder head temperature sensor (CHT) 18 - 20 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 3363 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor Engine Temperature Sensor: Description and Operation CHT Sensor The CHT sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends a signal to the PCM indicating cylinder head temperature. ^ If the temperature exceeds 126°C (258°F) 5.4L, 130°C (265°F) 4.6L, the PCM disables four fuel injectors at a time. The PCM will alternate which four fuel injectors are disabled every 32 engine cycles. The four cylinders the are not being fuel injected act as air pumps to aid in cooling the engine. ^ If the temperature exceeds 154°C (310°F) 5.4L, 166°C (330°F) 4.6L, the PCM disables all of the fuel injectors until the engine temperature drops below 154°C (310°F) 5.4L, 153°C (308°F) 4.6L. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor > Page 3366 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor communicates an overheating condition to the PCM. The PCM would then initiate a cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using a CHT sensor and cooling strategy would prevent damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > Page 3367 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting or jacking an air suspension vehicle.This can be accomplished by turning off the air suspension switch located below the glove box in the lower right of the passenger foot well. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during the operations. Failure to follow the instructions may result in personal injury. Raise the vehicle on a hoist. 2. Remove the right front fender splash shield. 3. Remove the dual converter Y-pipe. 4. Remove the components in the order indicated in the following illustration and table. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Water temperature indicator sender unit 15 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 3371 Temperature Sensor (Gauge): Description and Operation Engine Coolant Temperature Gauge Engine coolant temperature information is received by the instrument cluster from the PCM over the SCP network. Temperatures over 121°C (275°F) will display hot (H). If the engine coolant temperature data is missing or invalid for five seconds, the instrument cluster will move the engine coolant temperature gauge below the cold (C) position. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Water thermostat start to open temperature 188 - 195 F Water thermostat full open temperature 212 F Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3378 Thermostat: Service and Repair Removal and Installation 1. Partially drain the engine cooling system. 2. Disconnect the upper radiator hose from the water outlet adapter. 3. Remove the water outlet adapter. 1 Remove the bolts. 2 Remove the water outlet adapter. 4. Remove the (A) water thermostat and the (B) O-ring seal. Discard the (B) O-ring seal. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Thermostat housing bolts 15 - 22 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Water Pump Water Pump: Specifications Water pump bolts 15 - 22 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Water Pump > Page 3386 Water Pump: Specifications Water pump pulley bolts 15 - 22 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3387 Water Pump: Service and Repair Removal and Installation 1. Remove the engine cooling fan and fan shroud. 2. Remove the drive belt. 3. Remove the water pump pulley. 4. Remove the water pump. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3393 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3394 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3395 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3396 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3397 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3398 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3399 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3400 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3401 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3402 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3403 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3404 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3405 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3406 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3407 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3408 Catalytic Converter: Specifications Three way catalytic converter to exhaust manifold nuts 30 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3409 Generic Catalyst and Exhaust System Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3410 Catalytic Converter: Description and Operation Overview Generic Catalyst and Exhaust System 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). CO, NOx, and HCs are major air pollutants, and their emission into the atmosphere must be controlled. The exhaust system generally consists of an exhaust manifold, front exhaust pipe, upstream Heated Oxygen Sensor (HO2S), rear exhaust pipe, downstream HO2S, a muffler and an exhaust tailpipe. The catalytic converter is installed between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the On Board Diagnostic (OBD II) system. (Refer to OBD II Monitors to Catalyst Efficiency Monitor-Federal Test Procedure for specific information.) Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst will also enable a chemical reaction to occur at a lower temperature. The concentration of exhaust gas products released to the atmosphere must be controlled. The catalytic converter assists in this task. It contains a catalyst in the form of a specially treated 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. Exhaust System 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. An HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of Carbon Monoxide (CO), unburned Hydrocarbons (HCs) and Oxides Of Nitrogen (NOx) in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter to a muffler through the rear exhaust pipe. Another HO2S is mounted on the rear exhaust pipe. Lastly, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. HARDWARE The downstream HO2S may be located after the light off catalyst or underbody catalyst. The underbody catalyst may be in-line with the light off catalyst, or the underbody catalyst may be common to two light off catalysts, forming a "Y" pipe configuration. For an exact configuration of the catalyst and exhaust system, refer to Exhaust System. Three Way Catalytic Converter The Three Way Catalytic (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 three-way conversion can br brst 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 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3411 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. Upstream Heated and Downstream Heated Oxygen Sensors The HO2S provide the Powertrain Control Module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. (Refer to the PCM Inputs for a description of how the H02S operates.) In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the H02S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. (Refer to the OBD II Monitors for specific information on these monitors.) 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 it also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3412 Catalytic Converter: Service and Repair Removal and Installation All vehicles 1. Prepare the vehicle for dual converter Y-pipe removal. 1 Raise and support the vehicle. 2 Remove the muffler and tail pipe assembly. 2. Disconnect the two Heated Oxygen Sensor (H02S) electrical connectors. 3. Disconnect the two catalyst monitor sensor electrical connectors. 4. Remove the nuts. Vehicles equipped with transfer case skid plate 5. Remove the bolts, and the transfer case skid plate. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3413 All vehicles 6. Remove the two bolts retaining the heat shield to the transmission support crossmember bolts. 7. Using a suitable High-Lift jack, support the transmission. 8. Remove the nuts. 9. Remove the bolts, the nuts, and the transmission support crossmember. Vehicles with 4.6L engine 10. Remove the nut. Vehicles with 5.4L engine Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3414 11. Remove the bolt. All vehicles 12. Remove the clamp. 13. Note: It may be necessary to heat the dual converter Y-pipe joint to ease removal. Remove the dual converter Y-pipe. 14. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Manifold: > 09-22-8 > Nov > 09 > Exhaust System - Broken Exhaust Manifold Studs Exhaust Manifold: Customer Interest Exhaust System - Broken Exhaust Manifold Studs TSB 09-22-8 11/16/09 STAINLESS STEEL EXHAUST STUDS - 5.4L AND 6.8L 2V ENGINES FORD: 1997-2004 Expedition, F-150 1999-2010 E-Series, F-Super Duty 2000-2005 Excursion LINCOLN: 1998-1999 Navigator This article supersedes TSB 5-5-4 to update the vehicle model years and engine application. ISSUE Some 1997-2010 F-Series, 1999-2010 E-Series, 2000-2005 Excursion, 1997-2004 Expedition and 1998-1999 Navigators equipped with the 5.4L or 6.8L 2-valve (non supercharged) engine, may exhibit broken exhaust manifold studs. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Refer to Workshop Manual, Section 303-01 for exhaust manifold removal and installation for the affected engine bank only. 1. Replace exhaust manifold. 2. Replace manifold gasket. 3. Install all new stainless steel exhaust manifold studs and nuts. 4. Torque the studs in the cylinder head to 71-115 lb-in (8-13 N.m). 5. Torque nuts on studs to 204-239 lb-in (23-27 N.m). 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 MT092208 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 9430 24 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Manifold: > 09-22-8 > Nov > 09 > Exhaust System - Broken Exhaust Manifold Studs > Page 3423 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Manifold: > 09-22-8 > Nov > 09 > Exhaust System Broken Exhaust Manifold Studs Exhaust Manifold: All Technical Service Bulletins Exhaust System - Broken Exhaust Manifold Studs TSB 09-22-8 11/16/09 STAINLESS STEEL EXHAUST STUDS - 5.4L AND 6.8L 2V ENGINES FORD: 1997-2004 Expedition, F-150 1999-2010 E-Series, F-Super Duty 2000-2005 Excursion LINCOLN: 1998-1999 Navigator This article supersedes TSB 5-5-4 to update the vehicle model years and engine application. ISSUE Some 1997-2010 F-Series, 1999-2010 E-Series, 2000-2005 Excursion, 1997-2004 Expedition and 1998-1999 Navigators equipped with the 5.4L or 6.8L 2-valve (non supercharged) engine, may exhibit broken exhaust manifold studs. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Refer to Workshop Manual, Section 303-01 for exhaust manifold removal and installation for the affected engine bank only. 1. Replace exhaust manifold. 2. Replace manifold gasket. 3. Install all new stainless steel exhaust manifold studs and nuts. 4. Torque the studs in the cylinder head to 71-115 lb-in (8-13 N.m). 5. Torque nuts on studs to 204-239 lb-in (23-27 N.m). 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 MT092208 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 9430 24 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Manifold: > 09-22-8 > Nov > 09 > Exhaust System Broken Exhaust Manifold Studs > Page 3429 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Page 3430 Exhaust Manifold: Specifications Exhaust manifold nuts 17 - 20 ft.lb LH Sequence --RH Sequence --Exhaust manifold studs 89 - 115 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH Exhaust Manifold: Service and Repair LH Removal All Vehicles 1. Raise and support the vehicle. 2. On 4x4 vehicles, remove the front wheel opening molding. 3. Remove the front fender splash shield. 4. Note: Romeo engine shown; Windsor engine similar. Remove the nut and the brake booster vacuum hose bracket. 4.6L Engine 5. Disconnect the EGR valve to exhaust manifold tube connections: - The EGR bake pressure transducer hoses. - The EGR valve to exhaust manifold tube upper fitting. - The EGR valve to exhaust manifold tube lower fitting and remove the EGR valve to exhaust manifold tube. 5.4L Engine Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH > Page 3433 All Vehicles 6. Remove the nuts. 7. Remove the (A) nuts and the (B) exhaust manifold. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH > Page 3434 8. Remove and discard the exhaust manifold gasket. 9. Clean and inspect the exhaust manifold. Installation All Vehicles 1. Position the exhaust manifold gasket. 2. Position the (B) exhaust manifold and loosely install the (A) nuts. 3. Tighten the nuts in the sequence shown. 4. Install the three-way catalytic converter to exhaust manifold nuts. 4.6L Engine Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH > Page 3435 5. Connect the EGR valve to exhaust manifold tube upper fitting. - On 4.6L engines, tighten both fittings starting at the top in two stages. ^ Stage 1: Hand-tighten. ^ Stage 2: Tighten to 40 Nm (30 ft. lbs.). - On 5.4L engines, tighten both fittings starting at the top in two stages. ^ Stage 1: Hand-tighten. ^ Stage 2: Tighten to 40 - 60 Nm (30 - 44 ft. lbs.). 5.4L Engine All Vehicles Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH > Page 3436 6. Note: 4.6L engine shown; 5.4L engine similar. Position the brake booster vacuum hose bracket and install the nut. 7. Install the front fender splash shield. 8. On 4x4 vehicles, install the front wheel opening molding. 9. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH > Page 3437 Exhaust Manifold: Service and Repair RH Removal 1. Raise and support the vehicle. 2. On 4x4 vehicles, remove the front wheel opening molding. 3. Remove the front fender splash shield. 4. Note: 4.6L engine shown; 5.4L engine similar. Remove the three-way catalytic converter to exhaust manifold nuts. 5. Remove the eight (A) nuts and the (B) exhaust manifold. 6. Remove and discard the exhaust manifold gasket. 7. Clean and inspect the exhaust manifold. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > LH > Page 3438 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications Heat Shield: Specifications Heat shield screws 11 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 3442 Heat Shield: Service and Repair Removal and Installation 1. Raise and support the vehicle. 2. Inspect the exhaust system for loose or missing heat shields. 3. If any heat shields are loose, install worm gear clamps. - Use one of the following clamps: F0TZ-5A231-A or W705949-S300. - Trim off the excess ear of the worm clamp. 4. If the heat shields are missing, install new heat shields or exhaust system components as necessary. 5. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications Muffler: Specifications Muffler mounting bracket and insulator assembly to crossmember mounting bolts 15 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3457 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3458 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3459 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3465 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3466 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3471 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3472 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3473 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3479 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3480 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3481 Powertrain Control Module: Specifications Powertrain Control Module (PCM) Electrical Connector Bolt 5 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3482 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3483 Powertrain Control Module: Diagrams Part 1 Of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3484 Part 2 Of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3485 Part 3 Of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Engine Emission Control Powertrain Control Module: Description and Operation Engine Emission Control The powertrain control module controls the EGR vacuum regulator solenoid. The EGR vacuum regulator solenoid controls the vacuum to the EGR valve. When the EGR valve opens, exhaust gas flows to the intake manifold. The EGR transducer measures the flow through the EGR valve to exhaust manifold tube and sends a signal to the powertrain control module. A metering orifice in the EGR valve to exhaust manifold tube restricts the flow rate when the EGR valve is open. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Engine Emission Control > Page 3488 Powertrain Control Module: Description and Operation Electronic Engine Control The PCM needs the following inputs to calibrate the engine correctly: ^ engine rpm ^ engine coolant temperature ^ amount of engine detonation ^ crankshaft position ^ air temperature ^ throttle position ^ cylinder head temperature ^ mass air flow Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Page 3489 Powertrain Control Module: Testing and Inspection For information regarding diagnosis of this component refer to Computers and Control Systems Diagnosis. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures Powertrain Control Module: Procedures REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Loosen the bolt and disconnect the electrical connector. 3. Remove the RH front door scuff plate. 4. Remove the RH cowl side trim panel. 5. Remove the clip and the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 3492 Powertrain Control Module: Reset Procedure Flash Electrically Eraseable Programmable Read Only Memory-Flash EEPROM Flash Electrically Eraseable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internal to the PCM. The EEPROM contains the vehicle strategy including calibration information specific to the vehicle. The IC has the capability to be reprogrammed or reflashed. This is described below by the Flash EEPROM Procedure. As part of the calibration there is an area referred to as the Vehicle Identification (VID) Block. The VID block must be programmed when replacing the PCM and is described under Programming the VID Block for a Replacement PCM. The VID block is an existing PCM can also be tailored to accommodate various hardware changes made to the vehicle since production. This is described under Making Changes to the VID Block and also under the FLASH EEPROM Procedure. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VID number, octane adjust, fuel octane. fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, four wheel drive and manual versus non manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to reflash the PCM to reset the VID block. This is accomplished by the Flash EEPROM Procedure. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and in need of programming. There are two 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 will be performed if the old PCM is capable of communicating. This is done by the use of the scan tool to retrieve data from the old PCM before removing from the vehicle. The stored data can now be downloaded to the new PCM after replacing. This same process can also be accomplished during the Flash EEPROM Procedure described below. Manual data entry must be performed if the old module is damaged and not capable of communicating. Remove and replace the old PCM. Contact the "AS BUILT" data center by fax for the data needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used. The following information will need to be faxed in: dealer name, dealer P & A code, dealer phone number, dealer fax number, technician's name, VIN and module being programmed. The necessary VID block data will then be faxed back. Enter the vehicle data string provided by the "AS BUILT" data center. Refer to the Worldwide Diagnostic System users manual for details. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3496 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3497 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 3502 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 3503 The fuel pump relay is located in the battery junction box in the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 3504 Fuel Pump Relay: Description and Operation The fuel pump relay engages the fuel pump when energized by the PCM. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 3505 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3509 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3510 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow (MAF) Sensor Plate Nuts 10 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3516 Mass Air Flow Sensor: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3517 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3518 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3519 Mass Air Flow Sensor: Service Precautions CAUTION: ^ Do not tamper with the sensing elements located in the Mass Air Flow (MAF) sensor. Tampering may result in unit failure. ^ The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > General Mass Air Flow Sensor: Description and Operation General The MAF sensor: ^ sends the PCM a signal indicating mass airflow rate of air entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > General > Page 3522 Mass Air Flow Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (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 ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass 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. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > Page 3523 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Open the air cleaner. ^ Disconnect the MAF sensor extension harness connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the air cleaner from the outlet side of the air cleaner. CAUTION: Do not tamper with the sensing elements located in the Mass Air Flow (MAF) sensor. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and serviced as a unit. 2. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. 3. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > Page 3524 4. Remove the MAF sensor plate and the MAF sensor from the outlet side of the air cleaner. 5. Disconnect the MAF sensor electrical connector from the extension harness. 6. Separate the MAF sensor plate from the MAF sensor. ^ Remove the nuts from the MAF sensor plate. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to correctly align the inlet side and the outlet side of the air cleaner. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft position sensor bolt 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3528 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > General Camshaft Position Sensor: Description and Operation General The CMP sensor: ^ sends the PCM a signal indicating camshaft position used for fuel synchronization. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > General > Page 3531 Camshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 3532 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor 20 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft position sensor bolt 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3542 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (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 Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 3545 Crankshaft Position Sensor: Description and Operation Engine Ignition The CKP sensor: ^ is a variable reluctance sensor. ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. ^ provides base timing and crankshaft speed (rpm) to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 3546 Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 3547 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the A/C compressor. For additional information, refer to Heating and Air Conditioning. 2. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder head temperature sensor (CHT) 18 - 20 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 3551 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor Engine Temperature Sensor: Description and Operation CHT Sensor The CHT sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends a signal to the PCM indicating cylinder head temperature. ^ If the temperature exceeds 126°C (258°F) 5.4L, 130°C (265°F) 4.6L, the PCM disables four fuel injectors at a time. The PCM will alternate which four fuel injectors are disabled every 32 engine cycles. The four cylinders the are not being fuel injected act as air pumps to aid in cooling the engine. ^ If the temperature exceeds 154°C (310°F) 5.4L, 166°C (330°F) 4.6L, the PCM disables all of the fuel injectors until the engine temperature drops below 154°C (310°F) 5.4L, 153°C (308°F) 4.6L. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor > Page 3554 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor communicates an overheating condition to the PCM. The PCM would then initiate a cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using a CHT sensor and cooling strategy would prevent damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Page 3555 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting or jacking an air suspension vehicle.This can be accomplished by turning off the air suspension switch located below the glove box in the lower right of the passenger foot well. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during the operations. Failure to follow the instructions may result in personal injury. Raise the vehicle on a hoist. 2. Remove the right front fender splash shield. 3. Remove the dual converter Y-pipe. 4. Remove the components in the order indicated in the following illustration and table. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Pressure Sensor > Component Information > Description and Operation Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure Sensor Fuel Rail Pressure (FRP) Sensor Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. The Fuel Rail Pressure (FRP) sensor senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 3562 Fuel Tank Pressure Sensor: Service Precautions CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down while rotating the sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Fuel Tank Pressure Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor or Inline Fuel Tank Pressure (FTP) sensor is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 3565 Fuel Tank Pressure Sensor: Description and Operation The Fuel Tank Pressure (FTP) sensor: ^ monitors the pressure levels in the fuel tank. ^ communicates the pressure reading to the PCM during the OBD II leak test. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 3566 Fuel Tank Pressure Sensor: Description and Operation Principles of Operation The fuel tank pressure sensor is used to measure the fuel tank pressure during the Evaporative Emissions Monitor Test. It is also used to control excessive fuel tank pressures by forcing the system to purge. The FTP sensor is tank mounted. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 3567 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. For additional information, refer to Fuel Delivery and Air Induction. 2. Disconnect the electrical connector. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down while rotating the sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. 3. Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the system. For additional information, refer to Evaporative Emission System Leak Test. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Emission Control Systems/Evaporative Emissions System/Service and Repair Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation > General Intake Air Temperature Sensor: Description and Operation General The IAT sensor: ^ sends the PCM a signal indicating the temperature of the air entering the engine. ^ resistance decreases as temperature increases. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation > General > Page 3573 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors are thermistor devices in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and 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. Diagram Of Flow Through Throttle Body (Containing IAT Sensor Wire Where Applicable) Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. 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 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation > General > Page 3574 to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT sensor. Supercharged 5.4L Lightning vehicles use (2) IAT sensors. Both sensors operate as described above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation > Page 3575 Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 2. Remove the IAT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock sensor 13 - 16 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > General Knock Sensor: Description and Operation General The system has a unique linear KS located in the lifter valley. ^ The KS sends a signal to the PCM indicating engine detonation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > General > Page 3581 Knock Sensor: Description and Operation Knock Sensor Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 3582 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. For additional information, refer to Engine. 2. Remove the Knock Sensor (KS). 1 Disconnect the electrical connector. 2 Remove the nut and the KS. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications Oil Pressure Sensor: Specifications Oil Pressure sensor 107 - 142 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature The Engine Oil Temperature (EOT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and 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. Engine Coolant Temperature (ECT) Sensor The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the Engine Coolant Temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3593 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3594 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3595 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3596 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3597 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3598 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3599 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3600 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3601 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3602 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3603 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3604 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3605 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3606 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3607 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 3608 Heated Oxygen Sensor: Specifications Heated Oxygen Sensor 46 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 3609 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3612 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3613 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3614 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3615 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3616 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3617 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3618 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3619 Heated Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3620 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3621 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3622 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3623 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3624 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3625 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3626 Heated Oxygen Sensor: Connector Views Ford does not give the connector view. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 3627 Heated Oxygen Sensor: Application and ID 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 3628 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > General Heated Oxygen Sensor: Description and Operation General The HO2S: ^ has the ability to create a voltage signal dependent on exhaust oxygen content. ^ provides feedback information to the PCM used to calculate fuel delivery. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > General > Page 3631 Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor Heated Oxygen Sensor The Heated Oxygen Sensor (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 low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high 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. Heated Oxygen Sensor (HO2S) Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 3632 Heated Oxygen Sensor: Service and Repair EGO Sensor Wrench SPECIAL SERVICE TOOL(S) REMOVAL 1. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 2. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 3. Using the special tool, remove the HO2S. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 3633 EGO Sensor Wrench Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Bolts/Nuts 6 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3637 Pressure Feedback Exhaust Sensor: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3638 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3639 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback EGR Sensor Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor Differential Pressure Feedback 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 sensor receives this signal through two 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 aluminum 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. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback EGR Sensor > Page 3642 Pressure Feedback Exhaust Sensor: Description and Operation General The differential pressure feedback EGR sensor: ^ monitors the EGR flow rate through the EGR valve tube. ^ sends an EGR flow rate signal to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 3643 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the bolts and remove the engine appearance cover (if equipped). NOTE: The 4.6L engine is shown, the 5.4L engines are similar. 3. Remove the differential pressure feedback EGR. 1 Disconnect the electrical connector. 2 Disconnect the hoses. 3 Remove the bolts (nuts if applicable). INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > General Throttle Position Sensor: Description and Operation General The TP sensor: ^ sends the PCM a signal indicating the throttle plate angle. ^ is the main input to the PCM from the driver. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > General > Page 3649 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (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 three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 3650 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the bolts and the accelerator splash shield. 2. Disconnect the Throttle Position (TP) sensor electrical connector. 3. Remove the screws and the TP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission TR Sensor 71 - 88 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 3654 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > 4R70W Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > 4R70W > Page 3657 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 3658 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 3659 Digital Transmission Range Sensor: Service and Repair Special Tools Removal 1. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If this concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 3660 5. Remove the digital Transmission Range (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. Installation 1. Install the digital Transmission Range (TR) sensor. 1 Install digital Transmission Range (TR) sensor. 2 Loosely install the bolts. 2. Note: Make sure that the manual control lever is in the neutral position. Install the TRS Alignment Gauge. The TRS Alignment Gauge is designed to fit snug. 3. Tighten the bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 3661 4. Reconnect the shift cable at the manual control lever. 5. Reconnect the connector. 6. Lower the vehicle. 7. Reconnect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > General Vehicle Speed Sensor: Description and Operation General The VSS: ^ is gear driven by the transmission. ^ sends a signal to the PCM indicating vehicle speed. For additional information, refer to Automatic Transmission/Transaxle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > General > Page 3666 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Vehicle Speed Sensor Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission transaxle shift scheduling and torque converter clutch scheduling. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Bolts/Nuts 6 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3671 Pressure Feedback Exhaust Sensor: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3672 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3673 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback EGR Sensor Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor Differential Pressure Feedback 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 sensor receives this signal through two 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 aluminum 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. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback EGR Sensor > Page 3676 Pressure Feedback Exhaust Sensor: Description and Operation General The differential pressure feedback EGR sensor: ^ monitors the EGR flow rate through the EGR valve tube. ^ sends an EGR flow rate signal to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 3677 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the bolts and remove the engine appearance cover (if equipped). NOTE: The 4.6L engine is shown, the 5.4L engines are similar. 3. Remove the differential pressure feedback EGR. 1 Disconnect the electrical connector. 2 Disconnect the hoses. 3 Remove the bolts (nuts if applicable). INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow (MAF) Sensor Plate Nuts 10 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3682 Mass Air Flow Sensor: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3683 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3684 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3685 Mass Air Flow Sensor: Service Precautions CAUTION: ^ Do not tamper with the sensing elements located in the Mass Air Flow (MAF) sensor. Tampering may result in unit failure. ^ The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > General Mass Air Flow Sensor: Description and Operation General The MAF sensor: ^ sends the PCM a signal indicating mass airflow rate of air entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > General > Page 3688 Mass Air Flow Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (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 ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass 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. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > Page 3689 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Open the air cleaner. ^ Disconnect the MAF sensor extension harness connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the air cleaner from the outlet side of the air cleaner. CAUTION: Do not tamper with the sensing elements located in the Mass Air Flow (MAF) sensor. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and serviced as a unit. 2. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. 3. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > Page 3690 4. Remove the MAF sensor plate and the MAF sensor from the outlet side of the air cleaner. 5. Disconnect the MAF sensor electrical connector from the extension harness. 6. Separate the MAF sensor plate from the MAF sensor. ^ Remove the nuts from the MAF sensor plate. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to correctly align the inlet side and the outlet side of the air cleaner. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine Fuel Temperature Sensor The Engine Fuel Temperature (EFT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Fuel Temperature (EFT) Sensor The EFT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and Operation Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off 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 Guide for the location of the IFS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > General Throttle Position Sensor: Description and Operation General The TP sensor: ^ sends the PCM a signal indicating the throttle plate angle. ^ is the main input to the PCM from the driver. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > General > Page 3702 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (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 three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 3703 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the bolts and the accelerator splash shield. 2. Disconnect the Throttle Position (TP) sensor electrical connector. 3. Remove the screws and the TP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft position sensor bolt 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 3708 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > General Camshaft Position Sensor: Description and Operation General The CMP sensor: ^ sends the PCM a signal indicating camshaft position used for fuel synchronization. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > General > Page 3711 Camshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 3712 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft position sensor bolt 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3716 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (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 Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 3719 Crankshaft Position Sensor: Description and Operation Engine Ignition The CKP sensor: ^ is a variable reluctance sensor. ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. ^ provides base timing and crankshaft speed (rpm) to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 3720 Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 3721 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the A/C compressor. For additional information, refer to Heating and Air Conditioning. 2. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3727 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3728 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3729 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3730 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3731 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock sensor 13 - 16 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > General Knock Sensor: Description and Operation General The system has a unique linear KS located in the lifter valley. ^ The KS sends a signal to the PCM indicating engine detonation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > General > Page 3737 Knock Sensor: Description and Operation Knock Sensor Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Page 3738 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. For additional information, refer to Engine. 2. Remove the Knock Sensor (KS). 1 Disconnect the electrical connector. 2 Remove the nut and the KS. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve 7.75 Nm Fuel Pressure Relief Valve Cap 0.6 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3744 Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 700 - 760 RPM Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Locations > Page 3752 Air Filter Element: Service Precautions CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Locations > Page 3753 Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet Air Cleaner (ACL) aside. 2. Remove the (A) Air Cleaner (ACL) element from the (B) open end of the inlet air cleaner. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure the tabs are aligned properly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD . Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3758 Fuel Pressure Release: Service and Repair SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. ^ This will drain some fuel out of the system. Place the fuel in a suitable container. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3759 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications V8 Firing Order: 1 3 7 2 6 5 4 8 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 3763 Firing Order: Locations V8 Firing Order: 1 3 7 2 6 5 4 8 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plugs 9-20 Nm Original Spark Plug AWSF22E Replacement Spark Plug AWSF22E Spark Plug Gap 1.32-1.42 mm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 3772 Spark Plug: Specifications Spark Plugs 9-20 Nm Original Spark Plug AWSF22E Replacement Spark Plug AWSF22E Spark Plug Gap 1.32-1.42 mm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3773 Spark Plug: Application and ID Original Spark Plug Type ..................................................................................................................... ............................................................... AWSF22E Replacement Spark Plug Type .......................... ................................................................................................................................................... AWSF22E Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3774 Spark Plug: Description and Operation The spark plugs: ^ change a high voltage pulse into a spark which ignites the fuel and air mixture. ^ originally equipped on the vehicle have a platinum-enhanced electrode for long life. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal and Installation Spark Plug: Service and Repair Removal and Installation SPARK PLUG Engine Ignition - RH Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal and Installation > Page 3777 Engine Ignition - LH Exploded View Material Removal and Installation See TSB 8-1-9 Jan. 2008 1. Disconnect the ignition coil electrical connector. 2. NOTE: When removing the ignition coils, a slight twisting motion will break the seal and ease removal. Remove the bolt and the ignition coil. 3. NOTICE: Do not remove the spark plugs when the engine is hot or cold soaked. Spark plug thread or cylinder head damage can occur. Make sure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal and Installation > Page 3778 the engine is warm (hand touch after cooling down) prior to spark plug removal. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. Remove the spark plug in the following sequence. (1).Loosen the spark plug no more than one-eighth to one-fourth of a turn. (2).NOTICE: Excessive use of carburetor tune-up cleaner can introduce enough liquid volume to hydro-lock the engine. Using carburetor tune-up cleaner, fill the spark plug well until fluid has reached the spark plug jamb nut. Follow the directions on the packaging. (3).NOTICE: Do not loosen or tighten the spark plug for a minimum of 15 minutes or damage to the cylinder head or spark plug may occur. Let the carburetor tune-up cleaner soak for a minimum of 15 minutes. (4).NOTE: Some screeching and high effort may be noticed and is normal. NOTE: The expected removal torque is around 45 Nm (33 lb-ft). Tighten, and then loosen the spark plug, repeating until turning effort is reduced, and remove the spark plug. 4. Inspect the spark plug. Install a new spark plug as necessary. Installation 1. NOTICE: The spark plug gap is NOT adjustable. Damage can occur to the ceramic if the spark plug gap is adjusted. Install a new spark plug if the gap is out of specification. NOTE: Refer to the specifications in this section for correct spark plug identification. NOTE: Do not apply high temperature nickel anti-seize lubricant to the spark plug ground strap area. Apply high temperature nickel anti-seize lubricant to only the spark plug ground electrode shield as shown. 2. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. Install the spark plug. To install, tighten to 34 Nm (25 lb-ft). 3. NOTE: Verify that the ignition coil spring is correctly located inside the ignition coil-on-plug boot and that there is no damage to the tip of the boot. Install the ignition coil and the bolt. Apply a light coat of dielectric compound to the inside of the ignition coil boots. To install, tighten to 6 Nm (53 lb-in). 4. Connect the ignition coil electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal and Installation > Page 3779 Spark Plug: Service and Repair Spark Plug - Inspection REMOVAL 1. Remove the coil on plugs. For additional information refer to Ignition Coil. 2. Remove the spark plugs. NOTE: Remove any foreign material from the spark plug wells with compressed air before removing the spark plugs. 3. Inspect the spark plugs. For additional information, refer to Engine. 4. Adjust the spark plug gap as necessary. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 within 75 percent of the highest reading. For additional information, refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3783 Compression Check: Testing and Inspection General Remarks Note: Removing fuses and disconnecting electrical components causes the Powertrain Control Module (PCM) to log an error message. After the measurements have been carried out this error message should be cleared from memory by connecting to PDU. Note: Only check the compression pressure with the valves set to the prescribed clearance (if this can be adjusted). The compression pressure should be checked with the engine at operating temperature. Check The Compression Pressure WARNING: On manual transmissions shift the transmission into neutral. On automatic transmission vehicles, select "P". Failure to follow these instructions may result in personal injury. 1. Remove the fuel pump relay. 2. Start the engine-the engine will start, run for a few seconds then stall. 3. Remove the spark plugs. 4. Install the compression tester. 5. Install an auxiliary starter switch in the starting circuit. With the ignition switch OFF, using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 6. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. 7. Install the components in reverse order, observing the specified tightening torques. 8. Reset the PCM fault memory. Interpretation of the Results The indicated compression pressure are considered within specification if the lowest reading cylinder is within 75% of the highest reading. CAUTION: If engine oil is sprayed into the combustion chamber, after carrying out the measurement run the engine at 2000 rpm for about 15 minutes, in order to burn the oil and prevent damage to the catalytic converter. If the measurement on one or more cylinders is much lower than the specified value, spray some engine oil into the combustion chamber and repeat the compression measurement. If the reading greatly improves, the piston rings are damaged. If the reading stays the same, the cause is either damaged valve seats or valve stem seals. If the measurements for two cylinders next to each other arc both too low then it is very likely that the cylinder head gasket between them is burnt through. This can also be recognized by traces of engine oil in the coolant and/or coolant in the engine oil. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer does not indicate whether this vehicle has adjustable or non-adjustable valves. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow (MAF) Sensor Plate Nuts 10 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3791 Mass Air Flow Sensor: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3792 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3793 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3794 Mass Air Flow Sensor: Service Precautions CAUTION: ^ Do not tamper with the sensing elements located in the Mass Air Flow (MAF) sensor. Tampering may result in unit failure. ^ The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > General Mass Air Flow Sensor: Description and Operation General The MAF sensor: ^ sends the PCM a signal indicating mass airflow rate of air entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > General > Page 3797 Mass Air Flow Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (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 ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass 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. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > Page 3798 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Open the air cleaner. ^ Disconnect the MAF sensor extension harness connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the air cleaner from the outlet side of the air cleaner. CAUTION: Do not tamper with the sensing elements located in the Mass Air Flow (MAF) sensor. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and serviced as a unit. 2. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. 3. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > Page 3799 4. Remove the MAF sensor plate and the MAF sensor from the outlet side of the air cleaner. 5. Disconnect the MAF sensor electrical connector from the extension harness. 6. Separate the MAF sensor plate from the MAF sensor. ^ Remove the nuts from the MAF sensor plate. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to correctly align the inlet side and the outlet side of the air cleaner. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation > General Intake Air Temperature Sensor: Description and Operation General The IAT sensor: ^ sends the PCM a signal indicating the temperature of the air entering the engine. ^ resistance decreases as temperature increases. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation > General > Page 3805 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors are thermistor devices in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and 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. Diagram Of Flow Through Throttle Body (Containing IAT Sensor Wire Where Applicable) Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. 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 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation > General > Page 3806 to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT sensor. Supercharged 5.4L Lightning vehicles use (2) IAT sensors. Both sensors operate as described above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation > Page 3807 Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 2. Remove the IAT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest: > 02-10-8 > May > 02 > Fuel System - Whistling Noise Auxiliary Air Valve (Idle Speed): Customer Interest Fuel System - Whistling Noise Article No. 02-10-8 05/27/02 ^ DRIVEABILITY - 5.4L 2V - IDLE-AIR BYPASS FLOW INDUCED WHISTLE ^ ENGINE - 5.4L 2V - IDLE-AIR BYPASS FLOW INDUCED WHISTLE ^ NOISE - IDLE-AIR BYPASS FLOW INDUCED WHISTLE - VEHICLES EQUIPPED WITH 5.4L 2V ENGINE ONLY FORD: 1999-2002 E SERIES, EXPEDITION, F-150, SUPER DUTY F SERIES ISSUE Some vehicles equipped with the 5.4L 2V engine may exhibit a "whistling" noise from the formed nylon tube in the idle-air bypass flow circuit. This may be caused by air flow passing through the sharp bend radius of the original tube assembly. ACTION Remove and replace formed nylon tube with the Nipple And Hose Assembly 2L1Z-9W548-AA. This action will correct the sharp bend in the tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the formed tube as shown (Figure 1). 2. Replace with Nipple And Hose Assembly with part 2L1Z-9W548-AA. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest: > 02-10-8 > May > 02 > Fuel System - Whistling Noise > Page 3816 3. Connect nipple to the air-inlet zip tube and the free end connects to resonator as shown (Figure 2). 4. Ensure that there are no kinks in the rubber hose which could restrict air flow. LABOR OPERATION CLAIMING CHART PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9H308 V3 OASIS CODES: 497000, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-10-8 > May > 02 > Fuel System - Whistling Noise Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Fuel System - Whistling Noise Article No. 02-10-8 05/27/02 ^ DRIVEABILITY - 5.4L 2V - IDLE-AIR BYPASS FLOW INDUCED WHISTLE ^ ENGINE - 5.4L 2V - IDLE-AIR BYPASS FLOW INDUCED WHISTLE ^ NOISE - IDLE-AIR BYPASS FLOW INDUCED WHISTLE - VEHICLES EQUIPPED WITH 5.4L 2V ENGINE ONLY FORD: 1999-2002 E SERIES, EXPEDITION, F-150, SUPER DUTY F SERIES ISSUE Some vehicles equipped with the 5.4L 2V engine may exhibit a "whistling" noise from the formed nylon tube in the idle-air bypass flow circuit. This may be caused by air flow passing through the sharp bend radius of the original tube assembly. ACTION Remove and replace formed nylon tube with the Nipple And Hose Assembly 2L1Z-9W548-AA. This action will correct the sharp bend in the tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the formed tube as shown (Figure 1). 2. Replace with Nipple And Hose Assembly with part 2L1Z-9W548-AA. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-10-8 > May > 02 > Fuel System - Whistling Noise > Page 3822 3. Connect nipple to the air-inlet zip tube and the free end connects to resonator as shown (Figure 2). 4. Ensure that there are no kinks in the rubber hose which could restrict air flow. LABOR OPERATION CLAIMING CHART PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9H308 V3 OASIS CODES: 497000, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Auxiliary Air Valve (Idle Speed): > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Auxiliary Air Valve (Idle Speed): > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 3828 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Auxiliary Air Valve (Idle Speed): > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 3829 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Auxiliary Air Valve (Idle Speed): > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 3835 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Auxiliary Air Valve (Idle Speed): > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 3836 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft position sensor bolt 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3840 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > General Camshaft Position Sensor: Description and Operation General The CMP sensor: ^ sends the PCM a signal indicating camshaft position used for fuel synchronization. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > General > Page 3843 Camshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 3844 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor 20 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft position sensor bolt 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3854 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (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 Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 3857 Crankshaft Position Sensor: Description and Operation Engine Ignition The CKP sensor: ^ is a variable reluctance sensor. ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. ^ provides base timing and crankshaft speed (rpm) to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 3858 Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 3859 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the A/C compressor. For additional information, refer to Heating and Air Conditioning. 2. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3865 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3866 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3867 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3868 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3869 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3870 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3871 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3872 Data Link Connector: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3873 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3874 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3875 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3876 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3877 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3878 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3879 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Specifications EGR Backpressure Transducer: Specifications EGR back pressure transducer nuts 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3891 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3892 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3893 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3899 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3900 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3905 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3906 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3907 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3913 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3914 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3915 Powertrain Control Module: Specifications Powertrain Control Module (PCM) Electrical Connector Bolt 5 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3916 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3917 Powertrain Control Module: Diagrams Part 1 Of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3918 Part 2 Of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 3919 Part 3 Of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Engine Emission Control Powertrain Control Module: Description and Operation Engine Emission Control The powertrain control module controls the EGR vacuum regulator solenoid. The EGR vacuum regulator solenoid controls the vacuum to the EGR valve. When the EGR valve opens, exhaust gas flows to the intake manifold. The EGR transducer measures the flow through the EGR valve to exhaust manifold tube and sends a signal to the powertrain control module. A metering orifice in the EGR valve to exhaust manifold tube restricts the flow rate when the EGR valve is open. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Engine Emission Control > Page 3922 Powertrain Control Module: Description and Operation Electronic Engine Control The PCM needs the following inputs to calibrate the engine correctly: ^ engine rpm ^ engine coolant temperature ^ amount of engine detonation ^ crankshaft position ^ air temperature ^ throttle position ^ cylinder head temperature ^ mass air flow Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Page 3923 Powertrain Control Module: Testing and Inspection For information regarding diagnosis of this component refer to Computers and Control Systems Diagnosis. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures Powertrain Control Module: Procedures REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Loosen the bolt and disconnect the electrical connector. 3. Remove the RH front door scuff plate. 4. Remove the RH cowl side trim panel. 5. Remove the clip and the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 3926 Powertrain Control Module: Reset Procedure Flash Electrically Eraseable Programmable Read Only Memory-Flash EEPROM Flash Electrically Eraseable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internal to the PCM. The EEPROM contains the vehicle strategy including calibration information specific to the vehicle. The IC has the capability to be reprogrammed or reflashed. This is described below by the Flash EEPROM Procedure. As part of the calibration there is an area referred to as the Vehicle Identification (VID) Block. The VID block must be programmed when replacing the PCM and is described under Programming the VID Block for a Replacement PCM. The VID block is an existing PCM can also be tailored to accommodate various hardware changes made to the vehicle since production. This is described under Making Changes to the VID Block and also under the FLASH EEPROM Procedure. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VID number, octane adjust, fuel octane. fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, four wheel drive and manual versus non manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to reflash the PCM to reset the VID block. This is accomplished by the Flash EEPROM Procedure. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and in need of programming. There are two 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 will be performed if the old PCM is capable of communicating. This is done by the use of the scan tool to retrieve data from the old PCM before removing from the vehicle. The stored data can now be downloaded to the new PCM after replacing. This same process can also be accomplished during the Flash EEPROM Procedure described below. Manual data entry must be performed if the old module is damaged and not capable of communicating. Remove and replace the old PCM. Contact the "AS BUILT" data center by fax for the data needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used. The following information will need to be faxed in: dealer name, dealer P & A code, dealer phone number, dealer fax number, technician's name, VIN and module being programmed. The necessary VID block data will then be faxed back. Enter the vehicle data string provided by the "AS BUILT" data center. Refer to the Worldwide Diagnostic System users manual for details. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder head temperature sensor (CHT) 18 - 20 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 3930 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor Engine Temperature Sensor: Description and Operation CHT Sensor The CHT sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends a signal to the PCM indicating cylinder head temperature. ^ If the temperature exceeds 126°C (258°F) 5.4L, 130°C (265°F) 4.6L, the PCM disables four fuel injectors at a time. The PCM will alternate which four fuel injectors are disabled every 32 engine cycles. The four cylinders the are not being fuel injected act as air pumps to aid in cooling the engine. ^ If the temperature exceeds 154°C (310°F) 5.4L, 166°C (330°F) 4.6L, the PCM disables all of the fuel injectors until the engine temperature drops below 154°C (310°F) 5.4L, 153°C (308°F) 4.6L. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor > Page 3933 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor communicates an overheating condition to the PCM. The PCM would then initiate a cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using a CHT sensor and cooling strategy would prevent damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Page 3934 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting or jacking an air suspension vehicle.This can be accomplished by turning off the air suspension switch located below the glove box in the lower right of the passenger foot well. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during the operations. Failure to follow the instructions may result in personal injury. Raise the vehicle on a hoist. 2. Remove the right front fender splash shield. 3. Remove the dual converter Y-pipe. 4. Remove the components in the order indicated in the following illustration and table. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Pressure Sensor > Component Information > Description and Operation Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure Sensor Fuel Rail Pressure (FRP) Sensor Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. The Fuel Rail Pressure (FRP) sensor senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3941 Fuel Tank Pressure Sensor: Service Precautions CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down while rotating the sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Fuel Tank Pressure Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor or Inline Fuel Tank Pressure (FTP) sensor is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 3944 Fuel Tank Pressure Sensor: Description and Operation The Fuel Tank Pressure (FTP) sensor: ^ monitors the pressure levels in the fuel tank. ^ communicates the pressure reading to the PCM during the OBD II leak test. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 3945 Fuel Tank Pressure Sensor: Description and Operation Principles of Operation The fuel tank pressure sensor is used to measure the fuel tank pressure during the Evaporative Emissions Monitor Test. It is also used to control excessive fuel tank pressures by forcing the system to purge. The FTP sensor is tank mounted. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 3946 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. For additional information, refer to Fuel Delivery and Air Induction. 2. Disconnect the electrical connector. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down while rotating the sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. 3. Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the system. For additional information, refer to Evaporative Emission System Leak Test. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Emission Control Systems/Evaporative Emissions System/Service and Repair Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control Valve: Specifications Idle Air Control (IAC) Valve Bolts 10 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Description and Operation > General Idle Air Control Valve: Description and Operation General The IAC valve: ^ controls bypass air around the throttle plate at low speeds. ^ is controlled by the PCM. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Description and Operation > General > Page 3952 Idle Air Control Valve: Description and Operation Idle Air Control (IAC) Valve Idle Air Control Valve Nippondenso Idle Air Control (IAC) Valve Assembly Hitachi Idle Air Control (IAC) Valve Assembly with Vent/Filter Hitachi Idle Air Control (IAC) Valve Assembly with Air-Assist Injectors The Idle Air Control (IAC) valve assembly controls 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 AC duty cycle in order to achieve the desired rpm. On applications with air-assisted injectors, the IAC valve also supplies a small amount of air into the path of the fuel injectors. The jet of air causes an Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Description and Operation > General > Page 3953 increase in fuel atomization at low speed and light load conditions. NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED. The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the internal diode is measured in crossed terminal position with a digital multimeter, there will be an incorrect or negative reading. It is important that the mating component and harness connectors are correctly oriented. Diagnostic procedures emphasize this importance. 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. ^ Air Assist to Injectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Description and Operation > Page 3954 Idle Air Control Valve: Testing and Inspection Idle Air Control (IAC) Valve Check 1. Open the hood. 2. Verify the condition by operating the vehicle for a short time. NOTE: ^ Key symptom is elevated idle speed while noise is occurring. ^ "Snapping" the throttle can induce the noise. 3. Inspect the IAC valve. If physical evidence of contamination exists, install a new IAC valve. 4. While the noise is occurring, either place an EngineEAR probe near the IAC valve and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the IAC valve is making the noise, install a new IAC valve. 5. Test the vehicle for normal operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Description and Operation > Page 3955 Idle Air Control Valve: Service and Repair REMOVAL 1. Remove the bolts and the accelerator splash shield. 2. Disconnect the Idle Air Control (IAC) valve electrical connector. 3. Remove the two bolts and the IAC valve. INSTALLATION 1. To install, reverse the removal procedure. Install a new IAC valve gasket. Tighten the two bolts in 2 stages. ^ Stage 1: Tighten to 10 Nm (89 lb-in). ^ Stage 2: Rotate 90 degrees. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Specifications Multiplex Communication Network: Specifications Heat shrink tube overlap ...................................................................................................................... .................................................... 12.7 mm (0.5 inch) Wire insulation removal length (twist side) .............................................................................................................................................. 37.2 mm (1.5 inch) Wire insulation removal length (receiving side) ..................................................................................................................................... 19.5 mm (0.75 inch) Raychem SCT(R) heat shrink tubing, Motorcraft part number WT-5627 .................................................................................................. ESB-M99D56-A2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions Multiplex Communication Network: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3961 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3962 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3963 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3964 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3965 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3966 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3967 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3968 Multiplex Communication Network: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3969 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3970 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3971 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3972 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3973 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3974 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3975 Multiplex Communication Network: Electrical Diagrams Diagram 14-1 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 3976 Diagram 14-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 3979 Multiplex Communication Network: Description and Operation Principles and Operation The vehicle has two module communication networks. The Standard Corporate Protocol (SCP), which is an unshielded twisted-pair cable (data bus plus, circuit 914 and data bus minus, circuit 915 ) and the International Standards Organization (ISO) 9141 communications network, which is a single-wire network (circuit 70 [/WH]). Both networks can be connected to the scan tool through one connector called the Data Link Connector (DLC). The DLC can be found under the instrument panel between the steering column and the radio. The SCP communication network allows inter-module communication. This allows single inputs or outputs to be shared by multiple modules over common circuits. The SCP network will remain operational even with the severing of one of the bus wires. Communications will also continue if one of the bus wires is shorted to ground or power, or if some, but not all, termination resistors are lost. The PCM is the only module that contains termination resistors. The ISO 9141 communications network does not permit inter-module communication. When the scan tool communicates to modules on the ISO 9141 communication network, the scan tool initiates all communications. Unlike the SCP network, the ISO 9141 communication network will not function if the network is shorted to ground or power. Also, if one of the modules on the ISO 9141 communication network loses power or shorts internally, communications to that module will fail. The PCM is on the SCP communication network. The PCM controls the engine for better fuel economy, emissions control and failure mode detection and storage. This module also performs all Passive Anti-theft System (PATS) functions. For additional PCM information, refer to Powertrain Management. For PATS information, refer to Antitheft and Alarm Systems. The Restraint Control Module (RCM) is on the ISO 9141 communication network. The RCM controls the deployment of the air bags based on sensor input. For additional information, refer to Air Bag Systems. The Electronic Automatic Temperature Control (EATC) module is on the SCP communication network. The EATC module controls automatic climate functions that maintain the vehicle interior temperature at a constant setting. For additional information, refer to Heating and Air Conditioning. The Generic Electronic Module (GEM) is on the ISO 9141 communication network. The GEM controls a variety of systems: ^ windshield wipers ^ courtesy lamps ^ 4-wheel shift on the fly ^ warning chimes ^ one-touch down power windows For additional GEM information, refer to Multifunction Electronic Control Module. The Driver Seat Module (DSM) is on the ISO 9141 communication network. The DSM controls the positioning and programming of the driver seat, pedals and both outside mirrors. For additional information, refer to Seats. The Remote Anti-theft Personality (RAP) module is on the ISO 9141 communication network. The RAP module controls the remote entry, interior lamp illumination signal to the GEM and panic alarm from the keyless entry remote. For additional information, refer to Keyless Entry. The anti-lock brake control module is on the ISO 9141 communication network. The module controls brake pressure to the four wheels to keep the vehicle under control while braking. For additional information, refer to Antilock Brake System. The following describes the rear- and four-wheel air suspension modules: The air suspension control module is on the ISO 9141 communication network and controls the air compressor motor (through a solid state relay) and all system solenoids. The module also provides power to front and rear height sensors on four-wheel air suspension systems, or rear height sensors on the rear-wheel suspension systems. The module controls vehicle height adjustments by monitoring two height sensors, vehicle speed, a steering sensor, acceleration input, the door ajar signal, transfer case signals and the brake switch. The module also conducts all fail-safe and diagnostic strategies and contains self-test and communication software for testing the vehicle and module. The control module is mounted in the passenger compartment inside the instrument panel above the radio and temperature controls. The air suspension control module monitors and controls the system through a 32-pin two-way connector. It is keyed so that the control module cannot be plugged into an incorrect harness. There are two sides of the harness connection to the module. Each is uniquely colored and keyed to prevent reversal of connections. For additional information on the rear-wheel air suspension, refer to Electronic Level Control. For additional information on the four-wheel air suspension, refer to Electronic Level Control. The instrument cluster is on the SCP communication network. The instrument cluster is also called a Hybrid Electronic Cluster (HEC). It is an analog Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 3980 face cluster with a digital odometer. The instrument cluster displays a variety of information. For additional information, refer to Instrument Panel, Gauges and Warning Indicators. The Parking Aid Module (PAM) is connected to the ISO 9141 communication module. The module controls sensors in the rear bumper that detect close objects when the vehicle is in reverse. For additional information, refer to Collision Avoidance and Parking Assist Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Description and Operation > Description and Operation > Page 3981 Multiplex Communication Network: Description and Operation Principles of Operation Some modules support the ability to change specified factory configuration settings and preset preference items. The process used to change the settings and customer preference items is module configuration. This vehicle supports two methods of module configuration. ^ Customer preference items ^ Anti-theft configure Customer Preference Items This method is used to enable or disable module-controlled items or systems to suit the preference of the customer. Not all features controlled by the module are listed in this configuration method. Refer to the Module Configuration Index for a list of features per module. See: Testing and Inspection/Module Configuration/Scan Tool Testing/Module Configuration Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network Multiplex Communication Network: Testing and Inspection Module Communications Network Initial Inspection 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Fuse junction panel Fuse 3 (20A) ^ Damaged wiring harness ^ Lose or corroded connections 3. If the concern remains after the inspection, connect scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. If scan tool still does not communicate with the vehicle, go to Pinpoint Test M. See: Pinpoint Tests/Pinpoint Tests/Test M: No Module/Network Communication - No Power to Scan Tool 4. Go to Pinpoint Test PC. See: Pinpoint Tests/Pinpoint Test PC (Precheck) PC1 Test A: ABS Control Module Does Not Respond to the Scan Tool Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3984 A1 - A2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3985 A3 - A4 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3986 A5 - A6 Test B: RAP Module Does Not Respond to the Scan Tool Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3987 B1 - B2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3988 B3 - B4 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3989 B5 - B6 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3990 C1 - C2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3991 C3 - C4 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3992 D1 - D2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3993 D3 - D4 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3994 E1 - E2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3995 E3 - E4 Test F: DSM Does Not Respond To The Diagnostic Tool Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3996 F1 - F2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3997 F3 - F4 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3998 F5 - F6 Test G: PAM Module Does Not Respond to the Scan Tool Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 3999 G1 - G2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4000 G3 - G4 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4001 G5 - G6 Test H: PCM Does Not Respond To The Diagnostic Tool Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4002 H1 - H2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4003 H3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4004 H4 - H5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4005 H6 Test I: IC Module Does Not Respond to the Scan Tool Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4006 I1 - I2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4007 I3 I4 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4008 J1 - J2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4009 J3 - J4 Test K: No SCP Network Communication Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4010 K1 - K2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4011 K3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4012 K4 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4013 K5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4014 K6 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4015 K7 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4016 K8 - K9 Test L: No ISO 9141 Network Communication Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4017 L1 - L2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4018 L3 - L4 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4019 L5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4020 L6 - L7 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4021 L8 - L9 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4022 L10 - L11 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4023 L12 - L13 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4024 L14 - L15 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4025 L16 - L17 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4026 L18 - L19 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4027 M1 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4028 M2 - M4 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4029 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4030 Multiplex Communication Network: Testing and Inspection Module Configuration Initial Inspection 1. Visually inspect for obvious signs of electrical damage. Refer to the chart: VISUAL INSPECTION CHART Electrical Damaged wiring harness ^ Loose or corroded connectors ^ Generic Electronic Module (GEM) ^ Remote Anti-Theft Personality (RAP) 2. If the concern remains after inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch is in RUN position. 3. If the scan tool still does not communicate with the vehicle, refer to Module Communications Network. See: Module Communications Network 4. Refer to the Symptom Chart. See: Diagnosis By Symptom Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4031 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4032 A1 - A3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Service and Repair > Module Communications Network Wiring Repair Multiplex Communication Network: Service and Repair Module Communications Network Wiring Repair Communication Circuit Wiring Repair Heat Gun SPECIAL SERVICE TOOL(S) 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Strip the wires. 3. Solder the wires. 1 Install the heat shrink tube. 2 Twist the wires together. 3 Solder the wires together. NOTE: Use Rosin Core Mildly Activated (RMA) solder, not acid core solder. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Service and Repair > Module Communications Network Wiring Repair > Page 4035 4. Bend the wires back in a straight line. NOTE: Wait for the solder to cool before moving the wires. 5. Position the (A) heat shrink tube over the (B) wire repair. ^ Overlap the heat shrink tube on both wires. 6. Use the heat gun to heat the repaired area until adhesive flows out both ends of the heat shrink tube. 7. Reconnect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Service and Repair > Module Communications Network Wiring Repair > Page 4036 Multiplex Communication Network: Service and Repair Module Configuration Customer Preference Items NOTE: ^ If using the WDS, select Module Configuration and Programming, then follow the screen prompts. ^ Make sure module is listed as supporting customer preference items and supports the specific item to be configured in the Module Configuration Index. 1. Select Service Bay Functions on the scan tool. 2. Select the module that contains the customer preference item to be programmed. Refer to the Module Configuration Index. See: Testing and Inspection/Module Configuration/Scan Tool Testing/Module Configuration Index 3. Select Customer Preference Items on the scan tool. 4. Select Module Option Content. 5. Select the item to be enabled or disabled. 6. Enable or disable the item as necessary to reflect the customer preference. Module Configuration - Anti-Theft Configure NOTE: ^ If using the WDS, select Module Configuration and Programming, then follow the screen prompts. ^ Make sure module is listed as supporting anti-theft configure and supports the specific item to be configured in the Module Configuration Index. 1. Select Service Bay Functions on the scan tool. 2. Select the RAP module. 3. Select Anti-Theft Configure on the scan tool. 4. Select the item to be configured. ^ HORN CHIRP ^ PERSONALITY ^ AUTOLOCK/RELOCK ^ LED FLASH WHEN ARMED 5. Select the item to be enabled or disabled. 6. Enable or disable the item as necessary to reflect the customer preference. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Tools and Equipment > Tools and Equipment Multiplex Communication Network: Tools and Equipment Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network <--> [Information Bus] > Component Information > Tools and Equipment > Tools and Equipment > Page 4039 Multiplex Communication Network: Tools and Equipment Diagnostic Special Service Tool(S) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock sensor 13 - 16 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > General Knock Sensor: Description and Operation General The system has a unique linear KS located in the lifter valley. ^ The KS sends a signal to the PCM indicating engine detonation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > General > Page 4045 Knock Sensor: Description and Operation Knock Sensor Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 4046 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. For additional information, refer to Engine. 2. Remove the Knock Sensor (KS). 1 Disconnect the electrical connector. 2 Remove the nut and the KS. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4050 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4051 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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) Schematic CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) alerts the driver that the Powertrain Control Module (PCM) has detected an On Board Diagnostic (OBD) II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. ^ The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol. ^ Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. ^ The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. ^ If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. ^ If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. ^ To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. ^ For any MIL concern Symptom Charts. ^ If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. ^ If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications Oil Pressure Sensor: Specifications Oil Pressure sensor 107 - 142 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature The Engine Oil Temperature (EOT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and 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. Engine Coolant Temperature (ECT) Sensor The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the Engine Coolant Temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4065 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4066 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4067 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4068 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4069 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4070 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4071 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4072 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4073 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4074 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4075 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4076 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4077 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4078 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4079 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 4080 Heated Oxygen Sensor: Specifications Heated Oxygen Sensor 46 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 4081 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4084 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4085 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4086 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4087 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4088 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4089 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4090 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4091 Heated Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4092 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4093 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4094 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4095 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4096 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4097 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4098 Heated Oxygen Sensor: Connector Views Ford does not give the connector view. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 4099 Heated Oxygen Sensor: Application and ID 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 4100 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > General Heated Oxygen Sensor: Description and Operation General The HO2S: ^ has the ability to create a voltage signal dependent on exhaust oxygen content. ^ provides feedback information to the PCM used to calculate fuel delivery. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > General > Page 4103 Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor Heated Oxygen Sensor The Heated Oxygen Sensor (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 low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high 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. Heated Oxygen Sensor (HO2S) Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 4104 Heated Oxygen Sensor: Service and Repair EGO Sensor Wrench SPECIAL SERVICE TOOL(S) REMOVAL 1. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 2. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 3. Using the special tool, remove the HO2S. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 4105 EGO Sensor Wrench Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Bolts/Nuts 6 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4109 Pressure Feedback Exhaust Sensor: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4110 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4111 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback EGR Sensor Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor Differential Pressure Feedback 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 sensor receives this signal through two 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 aluminum 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. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback EGR Sensor > Page 4114 Pressure Feedback Exhaust Sensor: Description and Operation General The differential pressure feedback EGR sensor: ^ monitors the EGR flow rate through the EGR valve tube. ^ sends an EGR flow rate signal to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 4115 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the bolts and remove the engine appearance cover (if equipped). NOTE: The 4.6L engine is shown, the 5.4L engines are similar. 3. Remove the differential pressure feedback EGR. 1 Disconnect the electrical connector. 2 Disconnect the hoses. 3 Remove the bolts (nuts if applicable). INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 4125 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 4126 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 4127 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures > Page 4133 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures > Page 4134 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls DTC P1635 Set After PCM/IC Replacement > Page 4139 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls DTC P1635 Set After PCM/IC Replacement > Page 4140 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 02-23-4 > Nov > 02 > Engine Controls DTC P1635 Set After PCM/IC Replacement > Page 4141 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures Powertrain Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures > Page 4147 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Powertrain Control Module: > 04-24-14 > Dec > 04 > Engine Controls General PCM Programming Procedures > Page 4148 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4149 Powertrain Control Module: Specifications Powertrain Control Module (PCM) Electrical Connector Bolt 5 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4150 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4151 Powertrain Control Module: Diagrams Part 1 Of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4152 Part 2 Of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 4153 Part 3 Of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Engine Emission Control Powertrain Control Module: Description and Operation Engine Emission Control The powertrain control module controls the EGR vacuum regulator solenoid. The EGR vacuum regulator solenoid controls the vacuum to the EGR valve. When the EGR valve opens, exhaust gas flows to the intake manifold. The EGR transducer measures the flow through the EGR valve to exhaust manifold tube and sends a signal to the powertrain control module. A metering orifice in the EGR valve to exhaust manifold tube restricts the flow rate when the EGR valve is open. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Engine Emission Control > Page 4156 Powertrain Control Module: Description and Operation Electronic Engine Control The PCM needs the following inputs to calibrate the engine correctly: ^ engine rpm ^ engine coolant temperature ^ amount of engine detonation ^ crankshaft position ^ air temperature ^ throttle position ^ cylinder head temperature ^ mass air flow Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and Operation > Page 4157 Powertrain Control Module: Testing and Inspection For information regarding diagnosis of this component refer to Computers and Control Systems Diagnosis. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures Powertrain Control Module: Procedures REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Loosen the bolt and disconnect the electrical connector. 3. Remove the RH front door scuff plate. 4. Remove the RH cowl side trim panel. 5. Remove the clip and the PCM. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Procedures > Page 4160 Powertrain Control Module: Reset Procedure Flash Electrically Eraseable Programmable Read Only Memory-Flash EEPROM Flash Electrically Eraseable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internal to the PCM. The EEPROM contains the vehicle strategy including calibration information specific to the vehicle. The IC has the capability to be reprogrammed or reflashed. This is described below by the Flash EEPROM Procedure. As part of the calibration there is an area referred to as the Vehicle Identification (VID) Block. The VID block must be programmed when replacing the PCM and is described under Programming the VID Block for a Replacement PCM. The VID block is an existing PCM can also be tailored to accommodate various hardware changes made to the vehicle since production. This is described under Making Changes to the VID Block and also under the FLASH EEPROM Procedure. The VID block contains many items used by the strategy for a variety of functions. Some of these items include the VID number, octane adjust, fuel octane. fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control, four wheel drive and manual versus non manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to reflash the PCM to reset the VID block. This is accomplished by the Flash EEPROM Procedure. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and in need of programming. There are two 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 will be performed if the old PCM is capable of communicating. This is done by the use of the scan tool to retrieve data from the old PCM before removing from the vehicle. The stored data can now be downloaded to the new PCM after replacing. This same process can also be accomplished during the Flash EEPROM Procedure described below. Manual data entry must be performed if the old module is damaged and not capable of communicating. Remove and replace the old PCM. Contact the "AS BUILT" data center by fax for the data needed to manually update the VID block with the scan tool. Contact the center ONLY if the old PCM cannot be used. The following information will need to be faxed in: dealer name, dealer P & A code, dealer phone number, dealer fax number, technician's name, VIN and module being programmed. The necessary VID block data will then be faxed back. Enter the vehicle data string provided by the "AS BUILT" data center. Refer to the Worldwide Diagnostic System users manual for details. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4164 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4165 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow (MAF) Sensor Plate Nuts 10 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4170 Mass Air Flow Sensor: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4171 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4172 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4173 Mass Air Flow Sensor: Service Precautions CAUTION: ^ Do not tamper with the sensing elements located in the Mass Air Flow (MAF) sensor. Tampering may result in unit failure. ^ The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > General Mass Air Flow Sensor: Description and Operation General The MAF sensor: ^ sends the PCM a signal indicating mass airflow rate of air entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > General > Page 4176 Mass Air Flow Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (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 ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass 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. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > Page 4177 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Open the air cleaner. ^ Disconnect the MAF sensor extension harness connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the air cleaner from the outlet side of the air cleaner. CAUTION: Do not tamper with the sensing elements located in the Mass Air Flow (MAF) sensor. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and serviced as a unit. 2. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. 3. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > Page 4178 4. Remove the MAF sensor plate and the MAF sensor from the outlet side of the air cleaner. 5. Disconnect the MAF sensor electrical connector from the extension harness. 6. Separate the MAF sensor plate from the MAF sensor. ^ Remove the nuts from the MAF sensor plate. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to correctly align the inlet side and the outlet side of the air cleaner. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft position sensor bolt 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4182 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > General Camshaft Position Sensor: Description and Operation General The CMP sensor: ^ sends the PCM a signal indicating camshaft position used for fuel synchronization. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > General > Page 4185 Camshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 4186 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature (ECT) Sensor 20 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft position sensor bolt 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 4196 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (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 Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 4199 Crankshaft Position Sensor: Description and Operation Engine Ignition The CKP sensor: ^ is a variable reluctance sensor. ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. ^ provides base timing and crankshaft speed (rpm) to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 4200 Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Page 4201 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the A/C compressor. For additional information, refer to Heating and Air Conditioning. 2. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder head temperature sensor (CHT) 18 - 20 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 4205 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor Engine Temperature Sensor: Description and Operation CHT Sensor The CHT sensor: ^ is mounted into the wall of the cylinder head and is not connected to any coolant passages. ^ sends a signal to the PCM indicating cylinder head temperature. ^ If the temperature exceeds 126°C (258°F) 5.4L, 130°C (265°F) 4.6L, the PCM disables four fuel injectors at a time. The PCM will alternate which four fuel injectors are disabled every 32 engine cycles. The four cylinders the are not being fuel injected act as air pumps to aid in cooling the engine. ^ If the temperature exceeds 154°C (310°F) 5.4L, 166°C (330°F) 4.6L, the PCM disables all of the fuel injectors until the engine temperature drops below 154°C (310°F) 5.4L, 153°C (308°F) 4.6L. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > CHT Sensor > Page 4208 Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor Cylinder Head Temperature Sensor Cylinder Head Temperature (CHT) Sensor The Cylinder Head Temperature (CHT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor communicates an overheating condition to the PCM. The PCM would then initiate a cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. Using a CHT sensor and cooling strategy would prevent damage by allowing air cooling of the engine and limp home capability. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation > Page 4209 Engine Temperature Sensor: Service and Repair Cylinder Head Temperature (CHT) Sensor Removal and Installation 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting or jacking an air suspension vehicle.This can be accomplished by turning off the air suspension switch located below the glove box in the lower right of the passenger foot well. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during the operations. Failure to follow the instructions may result in personal injury. Raise the vehicle on a hoist. 2. Remove the right front fender splash shield. 3. Remove the dual converter Y-pipe. 4. Remove the components in the order indicated in the following illustration and table. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Pressure Sensor > Component Information > Description and Operation Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure Sensor Fuel Rail Pressure (FRP) Sensor Fuel Rail Pressure (FRP) Sensor The Fuel Rail Pressure (FRP) sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. The Fuel Rail Pressure (FRP) sensor senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4216 Fuel Tank Pressure Sensor: Service Precautions CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down while rotating the sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Fuel Tank Pressure Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Fuel Tank Pressure Sensor Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The Fuel Tank Pressure (FTP) sensor or Inline Fuel Tank Pressure (FTP) sensor is used to measure the fuel tank pressure during the EVAP monitor test on vehicles equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank pressure by forcing the system to purge. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 4219 Fuel Tank Pressure Sensor: Description and Operation The Fuel Tank Pressure (FTP) sensor: ^ monitors the pressure levels in the fuel tank. ^ communicates the pressure reading to the PCM during the OBD II leak test. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 4220 Fuel Tank Pressure Sensor: Description and Operation Principles of Operation The fuel tank pressure sensor is used to measure the fuel tank pressure during the Evaporative Emissions Monitor Test. It is also used to control excessive fuel tank pressures by forcing the system to purge. The FTP sensor is tank mounted. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation > Page 4221 Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. For additional information, refer to Fuel Delivery and Air Induction. 2. Disconnect the electrical connector. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down while rotating the sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. 3. Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak test the system. For additional information, refer to Evaporative Emission System Leak Test. See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General Diagnostics ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Emission Control Systems/Evaporative Emissions System/Service and Repair Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation > General Intake Air Temperature Sensor: Description and Operation General The IAT sensor: ^ sends the PCM a signal indicating the temperature of the air entering the engine. ^ resistance decreases as temperature increases. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation > General > Page 4227 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Intake Air Temperature Sensor Intake Air Temperature (IAT) The Intake Air Temperature (IAT) sensors are thermistor devices in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and 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. Diagram Of Flow Through Throttle Body (Containing IAT Sensor Wire Where Applicable) Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. 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 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation > General > Page 4228 to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and MAF. The IAT sensor provides a quicker temperature change response time than the ECT sensor. Supercharged 5.4L Lightning vehicles use (2) IAT sensors. Both sensors operate as described above. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Description and Operation > Page 4229 Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 2. Remove the IAT sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock sensor 13 - 16 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > General Knock Sensor: Description and Operation General The system has a unique linear KS located in the lifter valley. ^ The KS sends a signal to the PCM indicating engine detonation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > General > Page 4235 Knock Sensor: Description and Operation Knock Sensor Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 4236 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. For additional information, refer to Engine. 2. Remove the Knock Sensor (KS). 1 Disconnect the electrical connector. 2 Remove the nut and the KS. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Specifications Oil Pressure Sensor: Specifications Oil Pressure sensor 107 - 142 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature The Engine Oil Temperature (EOT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and 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. Engine Coolant Temperature (ECT) Sensor The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the Engine Coolant Temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4247 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4248 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4249 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4250 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4251 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4252 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4253 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4254 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4255 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4256 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4257 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4258 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4259 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4260 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4261 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 4262 Heated Oxygen Sensor: Specifications Heated Oxygen Sensor 46 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > Page 4263 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions Heated Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4266 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4267 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4268 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4269 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4270 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4271 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4272 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4273 Heated Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4274 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4275 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4276 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4277 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4278 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4279 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4280 Heated Oxygen Sensor: Connector Views Ford does not give the connector view. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 4281 Heated Oxygen Sensor: Application and ID 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams > Page 4282 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > General Heated Oxygen Sensor: Description and Operation General The HO2S: ^ has the ability to create a voltage signal dependent on exhaust oxygen content. ^ provides feedback information to the PCM used to calculate fuel delivery. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > General > Page 4285 Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor Heated Oxygen Sensor The Heated Oxygen Sensor (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 low voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a high 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. Heated Oxygen Sensor (HO2S) Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater and heater control system are installed on some vehicles. The high power heater reaches closed loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 4286 Heated Oxygen Sensor: Service and Repair EGO Sensor Wrench SPECIAL SERVICE TOOL(S) REMOVAL 1. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 2. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector. 3. Using the special tool, remove the HO2S. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description and Operation > Page 4287 EGO Sensor Wrench Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Bolts/Nuts 6 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4291 Pressure Feedback Exhaust Sensor: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4292 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4293 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback EGR Sensor Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor Differential Pressure Feedback 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 sensor receives this signal through two 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 aluminum 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. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback EGR Sensor > Page 4296 Pressure Feedback Exhaust Sensor: Description and Operation General The differential pressure feedback EGR sensor: ^ monitors the EGR flow rate through the EGR valve tube. ^ sends an EGR flow rate signal to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 4297 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the bolts and remove the engine appearance cover (if equipped). NOTE: The 4.6L engine is shown, the 5.4L engines are similar. 3. Remove the differential pressure feedback EGR. 1 Disconnect the electrical connector. 2 Disconnect the hoses. 3 Remove the bolts (nuts if applicable). INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > General Throttle Position Sensor: Description and Operation General The TP sensor: ^ sends the PCM a signal indicating the throttle plate angle. ^ is the main input to the PCM from the driver. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > General > Page 4303 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (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 three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 4304 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the bolts and the accelerator splash shield. 2. Disconnect the Throttle Position (TP) sensor electrical connector. 3. Remove the screws and the TP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission TR Sensor 71 - 88 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4308 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > 4R70W Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > 4R70W > Page 4311 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 4312 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 4313 Digital Transmission Range Sensor: Service and Repair Special Tools Removal 1. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If this concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 4314 5. Remove the digital Transmission Range (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. Installation 1. Install the digital Transmission Range (TR) sensor. 1 Install digital Transmission Range (TR) sensor. 2 Loosely install the bolts. 2. Note: Make sure that the manual control lever is in the neutral position. Install the TRS Alignment Gauge. The TRS Alignment Gauge is designed to fit snug. 3. Tighten the bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 4315 4. Reconnect the shift cable at the manual control lever. 5. Reconnect the connector. 6. Lower the vehicle. 7. Reconnect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > General Vehicle Speed Sensor: Description and Operation General The VSS: ^ is gear driven by the transmission. ^ sends a signal to the PCM indicating vehicle speed. For additional information, refer to Automatic Transmission/Transaxle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > General > Page 4320 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Vehicle Speed Sensor Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission transaxle shift scheduling and torque converter clutch scheduling. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > General Throttle Position Sensor: Description and Operation General The TP sensor: ^ sends the PCM a signal indicating the throttle plate angle. ^ is the main input to the PCM from the driver. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > General > Page 4326 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (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 three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 4327 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the bolts and the accelerator splash shield. 2. Disconnect the Throttle Position (TP) sensor electrical connector. 3. Remove the screws and the TP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission TR Sensor 71 - 88 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4331 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > 4R70W Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > 4R70W > Page 4334 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 4335 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 4336 Digital Transmission Range Sensor: Service and Repair Special Tools Removal 1. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If this concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 4337 5. Remove the digital Transmission Range (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. Installation 1. Install the digital Transmission Range (TR) sensor. 1 Install digital Transmission Range (TR) sensor. 2 Loosely install the bolts. 2. Note: Make sure that the manual control lever is in the neutral position. Install the TRS Alignment Gauge. The TRS Alignment Gauge is designed to fit snug. 3. Tighten the bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 4338 4. Reconnect the shift cable at the manual control lever. 5. Reconnect the connector. 6. Lower the vehicle. 7. Reconnect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > General Vehicle Speed Sensor: Description and Operation General The VSS: ^ is gear driven by the transmission. ^ sends a signal to the PCM indicating vehicle speed. For additional information, refer to Automatic Transmission/Transaxle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > General > Page 4343 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Vehicle Speed Sensor Vehicle Speed Sensor (VSS) The Vehicle Speed Sensor (VSS) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission transaxle shift scheduling and torque converter clutch scheduling. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4349 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4350 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4351 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4352 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4353 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4354 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4355 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4356 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4357 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4358 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4359 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4360 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4361 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4362 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4363 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4364 Catalytic Converter: Specifications Three way catalytic converter to exhaust manifold nuts 30 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4365 Generic Catalyst and Exhaust System Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4366 Catalytic Converter: Description and Operation Overview Generic Catalyst and Exhaust System 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). CO, NOx, and HCs are major air pollutants, and their emission into the atmosphere must be controlled. The exhaust system generally consists of an exhaust manifold, front exhaust pipe, upstream Heated Oxygen Sensor (HO2S), rear exhaust pipe, downstream HO2S, a muffler and an exhaust tailpipe. The catalytic converter is installed between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the On Board Diagnostic (OBD II) system. (Refer to OBD II Monitors to Catalyst Efficiency Monitor-Federal Test Procedure for specific information.) Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst will also enable a chemical reaction to occur at a lower temperature. The concentration of exhaust gas products released to the atmosphere must be controlled. The catalytic converter assists in this task. It contains a catalyst in the form of a specially treated 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. Exhaust System 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. An HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of Carbon Monoxide (CO), unburned Hydrocarbons (HCs) and Oxides Of Nitrogen (NOx) in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter to a muffler through the rear exhaust pipe. Another HO2S is mounted on the rear exhaust pipe. Lastly, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. HARDWARE The downstream HO2S may be located after the light off catalyst or underbody catalyst. The underbody catalyst may be in-line with the light off catalyst, or the underbody catalyst may be common to two light off catalysts, forming a "Y" pipe configuration. For an exact configuration of the catalyst and exhaust system, refer to Exhaust System. Three Way Catalytic Converter The Three Way Catalytic (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 three-way conversion can br brst 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 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4367 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. Upstream Heated and Downstream Heated Oxygen Sensors The HO2S provide the Powertrain Control Module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. (Refer to the PCM Inputs for a description of how the H02S operates.) In addition to providing the PCM with indications of how rich/lean the engine is operating, the upstream HO2S signal serves as an input to the H02S monitor. The downstream HO2S signal is an input to the Catalyst Efficiency monitor. (Refer to the OBD II Monitors for specific information on these monitors.) 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 it also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4368 Catalytic Converter: Service and Repair Removal and Installation All vehicles 1. Prepare the vehicle for dual converter Y-pipe removal. 1 Raise and support the vehicle. 2 Remove the muffler and tail pipe assembly. 2. Disconnect the two Heated Oxygen Sensor (H02S) electrical connectors. 3. Disconnect the two catalyst monitor sensor electrical connectors. 4. Remove the nuts. Vehicles equipped with transfer case skid plate 5. Remove the bolts, and the transfer case skid plate. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4369 All vehicles 6. Remove the two bolts retaining the heat shield to the transmission support crossmember bolts. 7. Using a suitable High-Lift jack, support the transmission. 8. Remove the nuts. 9. Remove the bolts, the nuts, and the transmission support crossmember. Vehicles with 4.6L engine 10. Remove the nut. Vehicles with 5.4L engine Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4370 11. Remove the bolt. All vehicles 12. Remove the clamp. 13. Note: It may be necessary to heat the dual converter Y-pipe joint to ease removal. Remove the dual converter Y-pipe. 14. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications Canister Purge Control Valve: Specifications Evaporative Emission Canister Purge Valve Bolts 8-10 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Specifications > Page 4375 Canister Purge Control Valve: Service Precautions WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA . Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Canister Purge Control Valve: Description and Operation 2000 All (Except diesel/Propane/Villager) EVAP Canister Purge Valve EVAP Canister Purge Valve Focus, Escort, Taurus/Sable, Mustang, and LS6/LS8 (EVAP Canister Purge Valve) The EVAP canister purge valve is the 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 normally closed valve. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 4378 Canister Purge Control Valve: Description and Operation The Evaporative Emission (EVAP) canister purge valve: ^ is normally closed. ^ regulates the purging of the EVAP canister. ^ is controlled by the PCM. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 4379 Canister Purge Control Valve: Description and Operation Principles of Operation (How Does It Work ?) The EVAP canister purge valve is controlled by the Powertrain Control Module (PCM). The EVAP canister purge valve controls the flow of fuel vapors from the EVAP canister to the engine intake manifold during various engine-operating modes. The EVAP canister purge valve is normally closed. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Description and Operation > Page 4380 Canister Purge Control Valve: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. 2. Disconnect the EVAP canister purge valve electrical connector and the evaporative emissions vacuum control hose. 3. Disconnect the two fuel vapor tubes. 1 Disconnect the EVAP canister purge outlet tube. 2 Disconnect the evaporative emission return tube. 4. Remove the bolts and remove the valve. INSTALLATION 1. To install, reverse the removal procedure. ^ Leak Test the system. For additional information, refer to Evaporative Emission System Leak Test. See: Testing and Inspection/Component Tests and General Diagnostics ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Description and Operation Canister Purge Solenoid: Description and Operation Canister Vent Solenoid Typical Canister Vent (CV) Solenoid During the Enhanced EVAP System test monitor, the Canister Vent (CV) solenoid seals the EVAP canister from atmospheric pressure. This allows the EVAP canister purge valve to obtain the target vacuum in the fuel tank during the monitor run. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications Evaporative Emission Control Canister: Specifications Evaporative Emissions Canister Nuts 15-20 Nm Evaporative Emissions Canister Bracket 8-10 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 4387 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 4388 Evaporative Emission Control Canister: Service Precautions WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA . Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Description and Operation > Description and Operation Evaporative Emission Control Canister: Description and Operation The Evaporative Emissions (EVAP) canister: ^ is located along the left frame rail behind the fuel tank. ^ contains activated carbon. ^ stores fuel vapors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Description and Operation > Description and Operation > Page 4391 Evaporative Emission Control Canister: Description and Operation Principles of Operation (How Does It Work ?) Fuel vapors from the fuel tank are stored in the EVAP canister. When the engine is running, the vapors are purged from the EVAP canister for combustion. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Description and Operation > Page 4392 Evaporative Emission Control Canister: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. 2. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 3. Disconnect the evaporative emissions canister vent solenoid electrical connector. 4. Loosen the clamp and remove the evaporative emission purge outlet tube. 5. Remove the nuts and remove canister and bracket assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Description and Operation > Page 4393 6. If required, remove the bolt and remove the EVAP canister from the bracket. 7. If required, remove the retainer. ^ Slide the retainer off the bracket. 8. Remove the evaporative emissions canister vent solenoid. NOTE: ^ Inspect and replace the O-ring as necessary. ^ A twisting and pulling motion is required to remove the evaporative emissions canister vent solenoid. 9. Remove canister inlet fitting. NOTE: ^ Inspect and replace the O-ring as necessary. ^ If required, a twisting and pulling motion is required to remove the inlet fitting. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Description and Operation > Page 4394 ^ Leak test the system. For additional information, refer to Evaporative Emission System Leak test. See: Testing and Inspection/Component Tests and General Diagnostics ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair NOTE: Lubricate O-ring seals with MERPOL(R) O-ring Seal Lubricant or equivalent meeting Ford specification ESE-M99B144-B. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Locations > Page 4398 Evaporative System Service Port: Description and Operation The Evaporative Emission (EVAP) system test port: ^ is located in the EVAP canister purge valve. ^ is used to connect the Evaporative Emissions System Leak Tester to the EVAP system. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 4402 Leak Detection Valve: Service Precautions CAUTION: The canister vent solenoid must not be energized for more than nine minutes at one time. Once the canister vent solenoid is energized and de-energized, adequate time must be allowed for the component to cool adequately. Failure to allow the component to cool may create a false failure in the diagnostics, causing unnecessary repairs. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Description and Operation > Description and Operation Leak Detection Valve: Description and Operation The canister vent solenoid: ^ is normally open. ^ seals the evaporative emissions system for the OBD II leak and pressure tests. ^ is mounted to the evaporative emissions canister. ^ is repaired as a separate item. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Description and Operation > Description and Operation > Page 4405 Leak Detection Valve: Description and Operation Principles of Operation (How Does It Work ?) During the Evaporative Emission Running Loss System Monitor Test, Evaporative Emissions Repair Verification Drive Cycle and the Evaporative Emission System Leak Test the canister vent solenoid is closed to allow either a vacuum to be drawn on the fuel tank or to hold a specified pressure in the system. The canister vent solenoid is normally open. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Description and Operation > Page 4406 Leak Detection Valve: Testing and Inspection Worldwide Diagnostic Systems (WDS) SPECIAL SERVICE TOOL(S) CAUTION: The canister vent solenoid must not be energized for more than nine minutes at one time. Once the canister vent solenoid is energized and de-energized, adequate time must be allowed for the component to cool adequately. Failure to allow the component to cool may create a false failure in the diagnostics, causing unnecessary repairs. 1. Connect the scan tool and select the output test mode. 2. Select the Fuel Tank Pressure (FTP) and the volts (V) Parameter Identification (PID) for monitoring. 3. Select the ALL OFF mode. 4. Close the canister vent solenoid by pushing the START button on the scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Description and Operation > Page 4407 Leak Detection Valve: Service and Repair REMOVAL 1. Remove the evaporative emission canister. 2. If required, remove the retainer. ^ Slide the retainer off the bracket. 3. Remove the evaporative emission canister vent solenoid. NOTE: ^ Inspect and replace the O-ring seal as necessary. ^ A twisting and pulling motion is required to remove the canister vent solenoid. INSTALLATION 1. To install, reverse the removal procedure. ^ Carry out the evaporative emission system leak test. For additional information, refer to Evaporative Emission System Leak Test. See: Testing and Inspection/Component Tests and General Diagnostics ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair NOTE: Lubricate O-ring seals with MEPOL(R) O-ring Seal Lubricant or equivalent meeting Ford specification ESE-M99B144-B. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Description and Operation > Page 4408 Worldwide Diagnostic Systems (WDS) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Locations > Page 4412 Liquid Vapor Separator: Service Precautions CAUTION: The fuel vapor vent valve must be disengaged from the fuel tank before it can be removed. Rotate the fuel vapor vent valve counterclockwise to disengage from the fuel tank. Failure to do so can cause damage to the fuel vapor vent valve or the fuel tank. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Locations > Page 4413 Liquid Vapor Separator: Description and Operation The Fuel Vapor Vent (FVV) valve assembly is mounted on the top of the fuel tank. It is used to control the flow of fuel vapors entering the EVAP system. The head portion of the assembly prevents the fuel tank from overfilling during refueling. The assembly also has a spring float, which prevents liquid fuel from entering the vapor delivery system under severe handling or vehicle rollover conditions. In the upright position the open bottom of the float will lift and shut off the orifice. Under severe handling conditions, the spring will push the float closed when angles allow liquid fuel to reach the orifice. In a rollover condition the weight of the open bottom float and spring pressure will close the orifice. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Locations > Page 4414 Liquid Vapor Separator: Service and Repair REMOVAL 1. Remove the fuel tank. For additional information, refer to Fuel Delivery and Air Induction. 2. Remove the fuel vapor vent valve. 1 Slide the clamp away from the evaporative emission valve and remove the evaporative emission return tube. 2 Press down and rotate the evaporative emission valve counterclockwise and remove it from the fuel tank. CAUTION: The fuel vapor vent valve must be disengaged from the fuel tank before it can be removed. Rotate the fuel vapor vent valve counterclockwise to disengage from the fuel tank. Failure to do so can cause damage to the fuel vapor vent valve or the fuel tank. INSTALLATION 1 To install, reverse the removal procedure. ^ Leak test the system. For additional information, refer to Evaporative Emission System Leak Test. See: Testing and Inspection/Component Tests and General Diagnostics ^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > System Information > Description and Operation Refueling Vapor Recovery System: Description and Operation On-Board Refueling Vapor Recovery (ORVR) Evaporative Emission (EVAP) System Focus, Escort, and Contour/Mystique/Cougar (ORVR EVAP System) LS6/LS8 (ORVR EVAP System) Board Refueling Vapor Recovery (ORVR) Evaporative Emission (EVAP) System Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > System Information > Description and Operation > Page 4418 The basic elements forming the ORVR system operation are as follows when fuel is dispensed: 1. The fuel filler pipe forms a seal to prevent vapors from escaping the fuel tank, while liquid is entering the fuel tank (liquid in the one inch diameter tube blocks vapors from rushing back up the fuel filler pipe). 2. A fuel vapor control valve controls the flow of vapors out of the fuel tank (valve closes when liquid level reaches a height associated with the fuel tank usable capacity). This valve accomplishes the following: a. Limits the total amount of fuel that can be dispensed into the fuel tank. b. Prevents liquid gasoline from exiting the fuel tank when submerged (and also when tipped well beyond a horizontal plane as part of the vehicle roll-over protection in road accidents). c. Minimizes vapor flow resistance during anticipated refueling conditions. 3. Fuel vapor tubing connects the fuel vapor control valve to the EVAP canister. This routes the fuel tank vapors (displaced by the incoming liquid) to the EVAP canister. 4. A check valve in the bottom of the fuel filler pipe prevents liquid from rushing back up the fuel filler pipe during the liquid flow variations associated with the filler nozzle shut-off. Between refueling events, the EVAP canister is purged with fresh air so that it may be used again to store vapors accumulated engine soaks or subsequent refueling events. The vapors drawn off of the carbon in the EVAP canister are consumed in the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Specifications EGR Backpressure Transducer: Specifications EGR back pressure transducer nuts 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications EGR Electronic Vacuum Regulator Solenoid: Specifications EGR Vacuum Regulator Solenoid Bolts/Nuts 6 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 4426 EGR Electronic Vacuum Regulator Solenoid: Locations LH Component RH Component Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Description and Operation > EGR Vacuum Regulator Solenoid EGR Electronic Vacuum Regulator Solenoid: Description and Operation EGR Vacuum Regulator Solenoid EGR Vacuum Regulator Solenoid EGR Vacuum Regulator Solenoid EGR Vacuum Regulator Solenoid Graph EGR Vacuum Regulator Solenoid Data The EGR vacuum regulator solenoid is an electromagnetic device which is used to regulate the vacuum supply to the EGR valve. The solenoid contains a coil which magnetically controls the position of a disc to regulate the vacuum. As the duty cycle to the coil increases, the vacuum signal passed through the solenoid to the EGR valve also increases. Vacuum not directed to the EGR valve is vented through the solenoid vent to atmosphere. Note that at 0% duty cycle (no electrical signal applied), the EGR vacuum regulator solenoid allows some vacuum to pass, but not enough to open the EGR valve. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Description and Operation > EGR Vacuum Regulator Solenoid > Page 4429 EGR Electronic Vacuum Regulator Solenoid: Description and Operation General The EGR vacuum regulator solenoid uses input from the PCM to change the EGR valve operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Description and Operation > Page 4430 EGR Electronic Vacuum Regulator Solenoid: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the bolts and remove the engine appearance cover (if equipped). NOTE: The 4.6L engine is shown, the 5.4L engines are similar. 3. Remove the Exhaust Gas Recirculation (EGR) vacuum regulator solenoid. 1 Disconnect the electrical connector. 2 Disconnect the vacuum lines. 3 Remove the bolts (nuts if applicable). INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications EGR Tube: Specifications EGR Valve To Exhaust Manifold Tube Fittings 40-60 Nm EGR Valve Tube Fitting 60 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 4434 EGR Tube: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 4435 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Description and Operation > General EGR Tube: Description and Operation General The EGR valve tube: ^ connects the exhaust manifold to the EGR valve. ^ has two tubes connecting to the differential pressure feedback EGR sensor for EGR flow monitoring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Description and Operation > General > Page 4438 EGR Tube: Description and Operation Orifice Tube Assembly Orifice Tube Assembly 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 two pressure pick-up tubes. The internal metering orifice creates a measurable pressure drop across it as the EGR valve opens and closes. This pressure differential across the orifice is picked up by the differential pressure feedback EGR sensor which provides feedback to the PCM. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Description and Operation > Page 4439 EGR Tube: Service and Repair REMOVAL 1. Remove the bolts and remove the engine appearance cover. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. 2. Remove the exhaust gas recirculation (EGR) valve tube. 1 Disconnect the upper and lower EGR valve tube fittings. 2 Disconnect the two differential pressure feedback EGR hoses. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Customer Interest for EGR Valve: > 05-4-17 > Mar > 05 > Emissions - Intermittent Rough Idle Condition EGR Valve: Customer Interest Emissions - Intermittent Rough Idle Condition TSB 05-4-17 03/07/05 INTERMITTENT ROUGH IDLE - NON-COMMANDED EGR FLOW FORD: 1997-1999 F-250 LD 1997-2004 F-150 1997-2005 E-Series 1998-2004 Expedition 1999-2004 F-Super Duty 2000-2005 Excursion LINCOLN: 1998-1999 Navigator ISSUE Some 1997-2005 5.4L 2V vehicles may exhibit an intermittent rough idle. This may be due to non-commanded EGR flow. ACTION EGR flow can be detected by comparing the stabilized DPFEGR KOER voltage (from NGS/WDS) at idle after manually opening and closing the EGR valve through 8 cycles. Record the DPFEGR voltage after each cycle. If the DPFEGR voltage increases by 0.03V or more from the stabilized idle voltage and is associated with a rough idle, the valve should be replaced. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Connect NGS/WDS and monitor DPFEGR PID. 2. Record initial stabilized DPFEGR voltage. 3. Disconnect the EGR valve vacuum line and connect hand held vacuum pump. 4. Raise RPM to prevent stalling and fully open the EGR valve. 5. Fully close valve and return to idle. 6. Record stabilized DPFEGR voltage. 7. Repeat Steps 4-6, eight (8) times. 8. If voltage increases by 0.03V or more with an associated rough idle condition during any of the cycles, the EGR valve may be sticking. Lightly tap the EGR valve casting and observe if voltage returns to initial DPFEGR value. a. If the DPFEGR voltage returns to the initial value and the associated rough idle is gone replace the EGR valve. b. If there is no change in DPFEGR voltage do not replace the EGR valve and perform normal diagnostics. 9. If the EGR valve is replaced repeat Steps 3-6, two (2) times to verify fix. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 050417A 1997-2005 Econoline 5.4L 0.9 Hr. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Customer Interest for EGR Valve: > 05-4-17 > Mar > 05 > Emissions - Intermittent Rough Idle Condition > Page 4448 2V: Replace The EGR Valve (Includes Time To Follow The Specific Diagnostic Steps Using WDS) (Do Not Use With 12650D, 12650D30) 050417A 2000-2004 F250/350 5.4L 1.0 Hr. 2V, 2000-2005 Excursion 5.4L 2V, 1998-1999 Navigator 5.4L 2V, 1998-2002 Expedition 5.4L 2V: Replace The EGR Valve (Includes Time To Follow The Specific Diagnostic Steps Using WDS) (Do Not Use With 12650D, 12650D30) 050417A 1999 F250/F350 5.4L 2V, 1.1 Hrs. 1999-2004 F-150 5.4L 2V SC, 1997-2004 F-150 5.4L 2V, 2003-2004 Expedition 5.4L 2V: Replace The EGR Valve (Includes Time To Follow The Specific Diagnostic Steps Using WDS) (Do Not Use With 12650D, 12650D30) DEALER CODING CONDITION BASIC PART NO. CODE 9D475 55 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for EGR Valve: > 05-4-17 > Mar > 05 > Emissions - Intermittent Rough Idle Condition EGR Valve: All Technical Service Bulletins Emissions - Intermittent Rough Idle Condition TSB 05-4-17 03/07/05 INTERMITTENT ROUGH IDLE - NON-COMMANDED EGR FLOW FORD: 1997-1999 F-250 LD 1997-2004 F-150 1997-2005 E-Series 1998-2004 Expedition 1999-2004 F-Super Duty 2000-2005 Excursion LINCOLN: 1998-1999 Navigator ISSUE Some 1997-2005 5.4L 2V vehicles may exhibit an intermittent rough idle. This may be due to non-commanded EGR flow. ACTION EGR flow can be detected by comparing the stabilized DPFEGR KOER voltage (from NGS/WDS) at idle after manually opening and closing the EGR valve through 8 cycles. Record the DPFEGR voltage after each cycle. If the DPFEGR voltage increases by 0.03V or more from the stabilized idle voltage and is associated with a rough idle, the valve should be replaced. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Connect NGS/WDS and monitor DPFEGR PID. 2. Record initial stabilized DPFEGR voltage. 3. Disconnect the EGR valve vacuum line and connect hand held vacuum pump. 4. Raise RPM to prevent stalling and fully open the EGR valve. 5. Fully close valve and return to idle. 6. Record stabilized DPFEGR voltage. 7. Repeat Steps 4-6, eight (8) times. 8. If voltage increases by 0.03V or more with an associated rough idle condition during any of the cycles, the EGR valve may be sticking. Lightly tap the EGR valve casting and observe if voltage returns to initial DPFEGR value. a. If the DPFEGR voltage returns to the initial value and the associated rough idle is gone replace the EGR valve. b. If there is no change in DPFEGR voltage do not replace the EGR valve and perform normal diagnostics. 9. If the EGR valve is replaced repeat Steps 3-6, two (2) times to verify fix. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 050417A 1997-2005 Econoline 5.4L 0.9 Hr. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for EGR Valve: > 05-4-17 > Mar > 05 > Emissions - Intermittent Rough Idle Condition > Page 4454 2V: Replace The EGR Valve (Includes Time To Follow The Specific Diagnostic Steps Using WDS) (Do Not Use With 12650D, 12650D30) 050417A 2000-2004 F250/350 5.4L 1.0 Hr. 2V, 2000-2005 Excursion 5.4L 2V, 1998-1999 Navigator 5.4L 2V, 1998-2002 Expedition 5.4L 2V: Replace The EGR Valve (Includes Time To Follow The Specific Diagnostic Steps Using WDS) (Do Not Use With 12650D, 12650D30) 050417A 1999 F250/F350 5.4L 2V, 1.1 Hrs. 1999-2004 F-150 5.4L 2V SC, 1997-2004 F-150 5.4L 2V, 2003-2004 Expedition 5.4L 2V: Replace The EGR Valve (Includes Time To Follow The Specific Diagnostic Steps Using WDS) (Do Not Use With 12650D, 12650D30) DEALER CODING CONDITION BASIC PART NO. CODE 9D475 55 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Page 4455 EGR Valve: Specifications EGR Valve Adapter Bolts 25 Nm EGR Valve Bolts 20 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Page 4456 EGR Valve: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Page 4457 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Page 4458 EGR Valve: Description and Operation Exhaust Gas Recirculation Valve Exhaust Gas Recirculation Valve Exhaust Gas Recirculation Valve Graph The EGR valve in the Differential Pressure Feedback EGR system is a conventional, vacuum-actuated EGR valve. The valve increases or decreases the flow of exhaust gas recirculation. 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 service specifications on flow rate is impractical. The on-board diagnostic system monitors the EGR valve function and triggers a Diagnostic Trouble Code if the test criteria is not met. The EGR valve flow rate is not measured directly as part of the field diagnostic procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Page 4459 EGR Valve: Service and Repair REMOVAL 1. Remove the air cleaner outlet tube. For additional information, refer to Fuel Delivery and Air Induction. 2. Disconnect the Exhaust Gas Recirculation (EGR) valve tube upper fitting. 3. Disconnect the EGR valve vacuum hose. 4. Remove the bolts and the EGR valve. ^ Discard the gasket. INSTALLATION 1. Carefully clean both sealing surfaces. ^ Install a new gasket. NOTE: The EGR valve sealing surfaces are soft metals. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Technical Service Bulletins > Page 4460 2. Install the EGR valve. Tighten the bolts in two stages: ^ Stage 1: Tighten to 20 Nm (15 lb-ft). ^ Stage 2: Tighten an additional 90 degrees. 3. Connect the EGR valve vacuum hose. 4. Connect the EGR valve to tube upper fitting. 5. Install the air cleaner outlet tube. For additional information, refer to Fuel Delivery and Air Induction. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Bolts/Nuts 6 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4464 Pressure Feedback Exhaust Sensor: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4465 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4466 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback EGR Sensor Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor Differential Pressure Feedback 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 sensor receives this signal through two 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 aluminum 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. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback EGR Sensor > Page 4469 Pressure Feedback Exhaust Sensor: Description and Operation General The differential pressure feedback EGR sensor: ^ monitors the EGR flow rate through the EGR valve tube. ^ sends an EGR flow rate signal to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 4470 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the bolts and remove the engine appearance cover (if equipped). NOTE: The 4.6L engine is shown, the 5.4L engines are similar. 3. Remove the differential pressure feedback EGR. 1 Disconnect the electrical connector. 2 Disconnect the hoses. 3 Remove the bolts (nuts if applicable). INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations RH Component Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 4475 Positive Crankcase Ventilation Valve: Description and Operation The PCV valve: ^ controls the amount of ventilating air and blow-by gases going to the intake manifold. ^ prevents a backfire from reaching the crankcase. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Bolts/Nuts 6 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4480 Pressure Feedback Exhaust Sensor: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4481 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4482 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback EGR Sensor Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR Sensor Differential Pressure Feedback EGR Sensor Differential Pressure Feedback 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 sensor receives this signal through two 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 aluminum 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. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Differential Pressure Feedback EGR Sensor > Page 4485 Pressure Feedback Exhaust Sensor: Description and Operation General The differential pressure feedback EGR sensor: ^ monitors the EGR flow rate through the EGR valve tube. ^ sends an EGR flow rate signal to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 4486 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the bolts and remove the engine appearance cover (if equipped). NOTE: The 4.6L engine is shown, the 5.4L engines are similar. 3. Remove the differential pressure feedback EGR. 1 Disconnect the electrical connector. 2 Disconnect the hoses. 3 Remove the bolts (nuts if applicable). INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve 7.75 Nm Fuel Pressure Relief Valve Cap 0.6 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 4492 Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD . Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 4496 Fuel Pressure Release: Service and Repair SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. ^ This will drain some fuel out of the system. Place the fuel in a suitable container. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 4497 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Hot Idle ................................................................................................................................................ ......................................................... 700 - 760 RPM Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Accelerator Pedal: Specifications Accelerator Pedal And Shaft Bolts 10 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 4504 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions Accelerator Pedal: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 4507 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 4508 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 4509 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 4510 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 4511 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 4512 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 4513 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 4514 Accelerator Pedal: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 4515 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 4516 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 4517 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 4518 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 4519 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 4520 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 4521 Accelerator Pedal: Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 4522 Accelerator Pedal: Electrical Diagrams Diagram 127-1 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 4523 Diagram 127-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Diagram Information and Instructions > Page 4524 Diagram 127-3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Diagrams > Page 4525 Accelerator Pedal: Description and Operation The throttle is controlled by an accelerator cable attached to the accelerator pedal and shaft assembly. The accelerator pedal and shaft should travel smoothly from the idle position to the wide open throttle position. Hesitation or binding should not be experienced at any portion of the accelerator pedal and shaft travel. Surrounding components such as wiring, hoses, sound insulator and floor carpet must not contact the sliding inner member of the accelerator cable, or interfere with the accelerator pedal and shaft. The vehicle is also available with an adjustable pedals option. This allows both the accelerator and brake pedals to be adjusted simultaneously forward or rearward. A rocker switch on the instrument panel provides adjustment on the pedals assembly when it is activated. On vehicles with the memory seat option, the pedals position can be controlled by the memory selection, as well as the rocker switch. The accelerator pedal and shaft can still be serviced separately on the adjustable pedals assembly. The components in the acceleration control system are not adjustable and must be replaced if damaged or worn. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accelerator Pedal: Initial Inspection and Diagnostic Overview 1. Verify the customer's concern by operating the acceleration control system to duplicate the condition. 2. Inspect to determine if any of the mechanical concerns apply: VISUAL INSPECTION CHART Mechanical ^ Damaged accelerator pedal and shaft ^ Damaged linkage ^ Damaged accelerator cable ^ High engine idle speed ^ Damaged throttle body ^ Damaged or binding adjustable pedal assembly 3. If the inspection reveals an obvious concern that can be readily identified, repair it as required. 4. If the concern remains after the inspection, determine the symptom(s) and go to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4528 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Adjustable Pedal Accelerator Pedal: Service and Repair Adjustable Pedal REMOVAL 1. Depress the locking tabs on the accelerator pedal drive cable and remove the drive cable from the accelerator pedal assembly. NOTE: Make sure that the adjustable pedals assembly is at the full forward position (pedals positioned toward front of the vehicle). The accelerator pedal and shaft can he serviced separately from the adjustable pedal assembly. However, the accelerator pedal and shaft itself is only serviced as an assembly. 2. Disconnect the accelerator cable from the accelerator pedal and shaft assembly. 3. Remove the bolts and remove the accelerator pedal and shaft assembly. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Adjustable Pedal > Page 4531 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Adjustable Pedal > Page 4532 Accelerator Pedal: Service and Repair Cable REMOVAL 1. Disconnect the accelerator cable from the accelerator pedal and shaft. 2. Remove the left hand side accelerator control splash shield bolts. 3. Remove the right hand side splash shield bolt and remove the splash shield. 4. Remove the accelerator cable clip. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Adjustable Pedal > Page 4533 5. Squeeze the accelerator cable lock tabs on the inside of the passenger compartment and push the accelerator cable into the engine compartment. 6. Depress the locking tabs and remove the accelerator cable from the accelerator cable bracket. 7. Disconnect the accelerator cable from the throttle lever. 1 Rotate the throttle lever forward. 2 Disconnect the accelerator cable from the throttle lever. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Adjustable Pedal > Page 4534 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Adjustable Pedal > Page 4535 Accelerator Pedal: Service and Repair Pedal REMOVAL 1. Disconnect the (A) accelerator cable from the (B) accelerator pedal and shaft. 2. Remove the bolts and remove the accelerator pedal and shaft. INSTALLATION 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Locations > Page 4540 Air Filter Element: Service Precautions CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Locations > Page 4541 Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet Air Cleaner (ACL) aside. 2. Remove the (A) Air Cleaner (ACL) element from the (B) open end of the inlet air cleaner. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure the tabs are aligned properly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow (MAF) Sensor Plate Nuts 10 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4545 Mass Air Flow Sensor: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4546 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4547 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4548 Mass Air Flow Sensor: Service Precautions CAUTION: ^ Do not tamper with the sensing elements located in the Mass Air Flow (MAF) sensor. Tampering may result in unit failure. ^ The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > General Mass Air Flow Sensor: Description and Operation General The MAF sensor: ^ sends the PCM a signal indicating mass airflow rate of air entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > General > Page 4551 Mass Air Flow Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (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 ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass 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. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > Page 4552 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Open the air cleaner. ^ Disconnect the MAF sensor extension harness connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the air cleaner from the outlet side of the air cleaner. CAUTION: Do not tamper with the sensing elements located in the Mass Air Flow (MAF) sensor. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and serviced as a unit. 2. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. 3. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > Page 4553 4. Remove the MAF sensor plate and the MAF sensor from the outlet side of the air cleaner. 5. Disconnect the MAF sensor electrical connector from the extension harness. 6. Separate the MAF sensor plate from the MAF sensor. ^ Remove the nuts from the MAF sensor plate. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to correctly align the inlet side and the outlet side of the air cleaner. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 02-10-8 > May > 02 > Fuel System - Whistling Noise Auxiliary Air Valve (Idle Speed): Customer Interest Fuel System - Whistling Noise Article No. 02-10-8 05/27/02 ^ DRIVEABILITY - 5.4L 2V - IDLE-AIR BYPASS FLOW INDUCED WHISTLE ^ ENGINE - 5.4L 2V - IDLE-AIR BYPASS FLOW INDUCED WHISTLE ^ NOISE - IDLE-AIR BYPASS FLOW INDUCED WHISTLE - VEHICLES EQUIPPED WITH 5.4L 2V ENGINE ONLY FORD: 1999-2002 E SERIES, EXPEDITION, F-150, SUPER DUTY F SERIES ISSUE Some vehicles equipped with the 5.4L 2V engine may exhibit a "whistling" noise from the formed nylon tube in the idle-air bypass flow circuit. This may be caused by air flow passing through the sharp bend radius of the original tube assembly. ACTION Remove and replace formed nylon tube with the Nipple And Hose Assembly 2L1Z-9W548-AA. This action will correct the sharp bend in the tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the formed tube as shown (Figure 1). 2. Replace with Nipple And Hose Assembly with part 2L1Z-9W548-AA. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 02-10-8 > May > 02 > Fuel System - Whistling Noise > Page 4562 3. Connect nipple to the air-inlet zip tube and the free end connects to resonator as shown (Figure 2). 4. Ensure that there are no kinks in the rubber hose which could restrict air flow. LABOR OPERATION CLAIMING CHART PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9H308 V3 OASIS CODES: 497000, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 02-10-8 > May > 02 > Fuel System - Whistling Noise Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Fuel System - Whistling Noise Article No. 02-10-8 05/27/02 ^ DRIVEABILITY - 5.4L 2V - IDLE-AIR BYPASS FLOW INDUCED WHISTLE ^ ENGINE - 5.4L 2V - IDLE-AIR BYPASS FLOW INDUCED WHISTLE ^ NOISE - IDLE-AIR BYPASS FLOW INDUCED WHISTLE - VEHICLES EQUIPPED WITH 5.4L 2V ENGINE ONLY FORD: 1999-2002 E SERIES, EXPEDITION, F-150, SUPER DUTY F SERIES ISSUE Some vehicles equipped with the 5.4L 2V engine may exhibit a "whistling" noise from the formed nylon tube in the idle-air bypass flow circuit. This may be caused by air flow passing through the sharp bend radius of the original tube assembly. ACTION Remove and replace formed nylon tube with the Nipple And Hose Assembly 2L1Z-9W548-AA. This action will correct the sharp bend in the tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the formed tube as shown (Figure 1). 2. Replace with Nipple And Hose Assembly with part 2L1Z-9W548-AA. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 02-10-8 > May > 02 > Fuel System - Whistling Noise > Page 4568 3. Connect nipple to the air-inlet zip tube and the free end connects to resonator as shown (Figure 2). 4. Ensure that there are no kinks in the rubber hose which could restrict air flow. LABOR OPERATION CLAIMING CHART PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9H308 V3 OASIS CODES: 497000, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4577 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4578 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4579 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4580 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4581 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4587 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4588 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4589 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4590 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4591 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Page 4592 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Description and Operation Fuel Filler Cap: Description and Operation The fuel tank filler cap: ^ relieves system pressure above 14 kPa (56.21 inches H2O). ^ relieves system vacuum below 3.8 kPa (15.26 inches H2O). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Description and Operation > Page 4595 Fuel Filler Cap: Description and Operation Principles of Operation (How Does It Work ?) The fuel filler cap is used to prevent fuel spill and to close the EVAP system to the atmosphere. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Description and Operation > Page 4596 Fuel Filler Cap: Description and Operation 2000 All (Except diesel/Propane/Villager) Fuel Filler Cap Fuel Filler Cap The fuel filler cap is used to prevent fuel spill and close the evaporative emission/fuel system to atmosphere. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD . Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 4601 Fuel Pressure Release: Service and Repair SPECIAL SERVICE TOOL(S) WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the schrader valve cap and install the EFI/CFI Fuel Pressure Gauge. 2. Open the manual valve slowly on the EFI/CFI Fuel Pressure Gauge and relieve the fuel pressure. ^ This will drain some fuel out of the system. Place the fuel in a suitable container. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 4602 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service Precautions Fuel Injector Wiring Harness: Service Precautions WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY . Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service Precautions > Page 4607 Fuel Injector Wiring Harness: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the wiring splash shield. 3. Loosen the bolt and disconnect the 42-pin engine bulkhead connector. 4. Disconnect the (A) fuel charging wiring electrical connector from the (B) engine control sensor wiring electrical connector. NOTE: The (A) fuel charging wiring electrical connector and the (B) engine control sensor wiring electrical connectors are located behind the (C) mount. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service Precautions > Page 4608 5. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 6. Remove the accelerator control splash shield. ^ Remove the bolts. ^ Remove the accelerator control splash shield. 7. Disconnect the following electrical connectors: ^ (A) Idle Air Control (IAC) valve electrical connector ^ (B) differential pressure feedback EGR transducer electrical connector ^ (C) Engine Vacuum Regulator (EVR) electrical connector ^ (D) Throttle Position (TP) sensor electrical connector 8. Disconnect the following electrical connectors: ^ (A) Engine Coolant Temperature (ECT) sensor electrical connector ^ (B) water temperature indicator sender unit electrical connector Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service Precautions > Page 4609 9. Disconnect the eight fuel injector electrical connectors. 10. Disconnect the eight ignition coil connectors. 11. Raise the vehicle. For additional information, refer to Maintenance/Service and Repair. 12. Disconnect the A/C compressor clutch electrical connector. NOTE: The A/C compressor clutch electrical connector can be reached through the wheel well. 13. Disconnect the two Heated Oxygen Sensor (HO2S) electrical connectors. NOTE: Engine removed for clarity. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Service Precautions > Page 4610 14. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 15. Disconnect the engine oil pressure sender unit electrical connector. 16. Lower the vehicle. 17. Remove the fuel charging wiring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Technician Safety Information Fuel Line Coupler: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA . Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Technician Safety Information > Page 4615 Fuel Line Coupler: Vehicle Damage Warnings CAUTION: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting Fuel Line Coupler: Service and Repair Hairpin Clip Fitting REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. CAUTION: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 1. Remove the shipping tab by bending it downward. 2. Spread the hairpin clip legs and push the clip into the fitting. 3. Separate the fitting from the tube. INSTALLATION 1. Inspect the fitting and the tube for damage. Remove any dirt or obstructions. 2. Apply a light coat of clean engine oil meeting Ford specification WSS-M2C153-F to the male tube end. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4618 3. insert the hairpin clip into the fitting. 4. Align the tube and the fitting. 5. Insert the tube in the fitting and push together until a click is heard. 6. Pull on the connection to make sure it is fully engaged. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4619 Fuel Line Coupler: Service and Repair Push Connect Fittings Fuel Line Disconnect Tool SPECIAL SERVICE TOOL(S) DISCONNECT WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Relieve the fuel pressure; refer to Fuel Pressure Release. 2. Disconnect the safety clip from the male hose. 3. Install the Fuel Line Disconnect Tool and push into the fitting. 4. Separate the fittings. ^ Inspect for damage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4620 ^ Clean the fittings. CONNECT 1. Align the tube to the fitting and push it until a click is heard. NOTE: Lubricate the tube end with clean engine oil meeting Ford specification WSS-M2C153-F to ease assembly. 2. Pull on the fitting to make sure it is fully engaged, then install the safety clip. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4621 Fuel Line Coupler: Service and Repair Spring Lock Couplings SPECIAL SERVICE TOOL(S) DISCONNECT WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Relieve the fuel pressure; refer to Fuel Pressure Release. 2. Remove the fuel tube clip. 3. Install the Disconnect Tool. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4622 4. Close and push the Disconnect Tool into the open side of the cage. 5. Separate the fitting. 6. Remove the Disconnect Tool. CONNECT 1. Follow the removal procedure in reverse order. ^ Inspect and clean both the coupling ends. ^ Lubricate the O-ring with clean engine oil meeting Ford specification WSS-M2C153-F. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Hairpin Clip Fitting > Page 4623 Fuel Line Coupler: Service and Repair Vapor Tube Fittings REMOVAL 1. Disconnect the battery ground cable. WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. 2. Disconnect the vapor tube from the fitting. 1 Squeeze the fitting. 2 Disconnect the vapor tube from the fitting. INSTALLATION 1. Inspect the fitting and the tube for damage. 2. Remove any dirt or obstructions. 3. Push the tube into the fitting until it snaps in place. 4. Pull on the connection to make sure the fitting is secure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 4624 Fuel Line Coupler: Tools and Equipment Fuel Line Disconnect Tool Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service Precautions > Technician Safety Information Fuel Pressure Regulator: Technician Safety Information WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY . Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Service Precautions > Technician Safety Information > Page 4630 Fuel Pressure Regulator: Vehicle Damage Warnings CAUTION: Use O-ring seals that are made of special fuel resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse the O-ring seals. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Fuel Pressure Regulator Fuel Pressure Regulator: Description and Operation Fuel Pressure Regulator Fuel Pressure Regulator Fuel Pressure Regulator The fuel pressure regulator is attached to the fuel rail downstream of the fuel injectors. It regulates fuel pressure supplied to the fuel injectors. The regulator is a diaphragm-operated relief valve. One side of the diaphragm senses fuel pressure and the other side is connected to the intake manifold vacuum. Fuel pressure is established by a spring preload applied to the diaphragm. Balancing one side of the diaphragm with manifold vacuum maintains a constant fuel pressure drop across the fuel injectors. Fuel pressure is high when engine vacuum is low. Excess fuel is bypassed through the fuel pressure regulator and returned through the fuel return line to the fuel tank. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Fuel Pressure Regulator > Page 4633 Fuel Pressure Regulator: Description and Operation General The fuel pressure regulator: ^ maintains constant fuel pressure throughout the fuel system and to the fuel injectors. ^ is spring-loaded and operated by intake manifold vacuum. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 4634 Fuel Pressure Regulator: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Relieve the fuel pressure. 2. Remove the fuel pressure regulator. 1 Disconnect the vacuum hose. 2 Remove the snap ring. 3 Remove the fuel pressure regulator. 3. Remove and discard the fuel pressure regulator O-ring seals. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Use O-ring seals that are made of special fuel resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse the O-ring seals. NOTE: Lubricate the new O-ring seals with clean Super Premium SAE5W-30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G, to aid installation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve 7.75 Nm Fuel Pressure Relief Valve Cap 0.6 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Specifications > Page 4638 Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 Pulse Damper Pulse Damper The fuel rail pulse damper located on the fuel rail reduces 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 in the event the pulse damper diaphragm were to rupture. (The pulse damper should not be confused with a fuel pressure regulator, it does not regulate fuel rail pressure.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel Pressure Relief Valve 7.75 Nm Fuel Pressure Relief Valve Cap 0.6 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 4647 Fuel Pressure Test Port: Description and Operation Pressure Test Point There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4651 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4652 The fuel pump relay is located in the battery junction box in the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4653 Fuel Pump Relay: Description and Operation The fuel pump relay engages the fuel pump when energized by the PCM. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4654 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4664 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4665 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4666 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4667 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4668 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4674 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4675 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4676 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4677 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4678 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4679 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4680 Fuel Filler Hose: Service Precautions WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD . Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4681 Fuel Filler Hose: Description and Operation The fuel filler pipe check valve is an intricate part of the fuel tank or the fuel filler pipe. It is intended to prevent liquid fuel from re-entering the fuel filler pipe from the fuel tank on refueling or rollover conditions. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4682 Fuel Filler Hose: Service and Repair REMOVAL WARNING: ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the fuel tank filler cap. 2. Remove the screws. 3. Loosen the hose clamp and disconnect the fuel filler vent hose from the fuel tank filler pipe. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4683 4. Disconnect the fuel tank to filler pipe hose and remove the fuel tank filler pipe. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4692 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4693 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4694 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4695 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4696 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4702 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4703 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4704 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4705 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4706 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation Fuel Gauge Sender: Description and Operation The "Gasoline System" information is not available at this time. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine Fuel Temperature Sensor The Engine Fuel Temperature (EFT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Fuel Temperature (EFT) Sensor The EFT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications Idle Air Control Valve: Specifications Idle Air Control (IAC) Valve Bolts 10 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Description and Operation > General Idle Air Control Valve: Description and Operation General The IAC valve: ^ controls bypass air around the throttle plate at low speeds. ^ is controlled by the PCM. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Description and Operation > General > Page 4718 Idle Air Control Valve: Description and Operation Idle Air Control (IAC) Valve Idle Air Control Valve Nippondenso Idle Air Control (IAC) Valve Assembly Hitachi Idle Air Control (IAC) Valve Assembly with Vent/Filter Hitachi Idle Air Control (IAC) Valve Assembly with Air-Assist Injectors The Idle Air Control (IAC) valve assembly controls 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 AC duty cycle in order to achieve the desired rpm. On applications with air-assisted injectors, the IAC valve also supplies a small amount of air into the path of the fuel injectors. The jet of air causes an Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Description and Operation > General > Page 4719 increase in fuel atomization at low speed and light load conditions. NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED. The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the internal diode is measured in crossed terminal position with a digital multimeter, there will be an incorrect or negative reading. It is important that the mating component and harness connectors are correctly oriented. Diagnostic procedures emphasize this importance. 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. ^ Air Assist to Injectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Description and Operation > Page 4720 Idle Air Control Valve: Testing and Inspection Idle Air Control (IAC) Valve Check 1. Open the hood. 2. Verify the condition by operating the vehicle for a short time. NOTE: ^ Key symptom is elevated idle speed while noise is occurring. ^ "Snapping" the throttle can induce the noise. 3. Inspect the IAC valve. If physical evidence of contamination exists, install a new IAC valve. 4. While the noise is occurring, either place an EngineEAR probe near the IAC valve and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the IAC valve is making the noise, install a new IAC valve. 5. Test the vehicle for normal operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Description and Operation > Page 4721 Idle Air Control Valve: Service and Repair REMOVAL 1. Remove the bolts and the accelerator splash shield. 2. Disconnect the Idle Air Control (IAC) valve electrical connector. 3. Remove the two bolts and the IAC valve. INSTALLATION 1. To install, reverse the removal procedure. Install a new IAC valve gasket. Tighten the two bolts in 2 stages. ^ Stage 1: Tighten to 10 Nm (89 lb-in). ^ Stage 2: Rotate 90 degrees. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and Operation Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off 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 Guide for the location of the IFS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Locations > Page 4728 Intake Air Duct: Service Precautions CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Locations > Page 4729 Intake Air Duct: Service and Repair REMOVAL 1. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the (A) positive crankcase ventilation hose and the (B) idle air control valve inlet tube. 4. Loosen the clamps and remove the air cleaner outlet tube and resonator. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Locations > Page 4730 CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4734 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4735 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 4740 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 4741 The fuel pump relay is located in the battery junction box in the left side of the engine compartment. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 4742 Fuel Pump Relay: Description and Operation The fuel pump relay engages the fuel pump when energized by the PCM. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 4743 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Powertrain Control Module Power Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4747 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4748 Powertrain Control Module Power Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications Mass Air Flow Sensor: Specifications Mass Air Flow (MAF) Sensor Plate Nuts 10 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4753 Mass Air Flow Sensor: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4754 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4755 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 4756 Mass Air Flow Sensor: Service Precautions CAUTION: ^ Do not tamper with the sensing elements located in the Mass Air Flow (MAF) sensor. Tampering may result in unit failure. ^ The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > General Mass Air Flow Sensor: Description and Operation General The MAF sensor: ^ sends the PCM a signal indicating mass airflow rate of air entering the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > General > Page 4759 Mass Air Flow Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Mass Air Flow Sensor Typical Mass Air Flow (MAF) Sensor The Mass Air Flow (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 ambient temperature as measured by a constant cold wire. If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass 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. Diagram Of Air Flow Through Throttle Body Containing MAF Sensor Hot And Cold Wire (and IAT Sensor Where Applicable) Terminals Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0 L Contour/Mystique, Cougar, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > Page 4760 Mass Air Flow Sensor: Service and Repair REMOVAL 1. Open the air cleaner. ^ Disconnect the MAF sensor extension harness connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the air cleaner from the outlet side of the air cleaner. CAUTION: Do not tamper with the sensing elements located in the Mass Air Flow (MAF) sensor. Tampering may result in unit failure. NOTE: The MAF sensor module and body are calibrated and serviced as a unit. 2. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. 3. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Description and Operation > Page 4761 4. Remove the MAF sensor plate and the MAF sensor from the outlet side of the air cleaner. 5. Disconnect the MAF sensor electrical connector from the extension harness. 6. Separate the MAF sensor plate from the MAF sensor. ^ Remove the nuts from the MAF sensor plate. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE: Use the alignment notch to correctly align the inlet side and the outlet side of the air cleaner. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation Fuel Temperature Sensor: Description and Operation Engine Fuel Temperature Sensor The Engine Fuel Temperature (EFT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. Engine Fuel Temperature (EFT) Sensor The EFT sensor measures the temperature of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Description and Operation Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The Inertia Fuel Shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off 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 Guide for the location of the IFS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > General Throttle Position Sensor: Description and Operation General The TP sensor: ^ sends the PCM a signal indicating the throttle plate angle. ^ is the main input to the PCM from the driver. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > General > Page 4773 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (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 three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 4774 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the bolts and the accelerator splash shield. 2. Disconnect the Throttle Position (TP) sensor electrical connector. 3. Remove the screws and the TP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Throttle Body Spacer > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications Throttle Cable/Linkage: Specifications Accelerator Cable Bracket Bolts 6 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 4782 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 4783 Throttle Cable/Linkage: Description and Operation The throttle is controlled by an accelerator cable attached to the accelerator pedal and shaft assembly. The accelerator pedal and shaft should travel smoothly from the idle position to the wide open throttle position. Hesitation or binding should not be experienced at any portion of the accelerator pedal and shaft travel. Surrounding components such as wiring, hoses, sound insulator and floor carpet must not contact the sliding inner member of the accelerator cable, or interfere with the accelerator pedal and shaft. The vehicle is also available with an adjustable pedals option. This allows both the accelerator and brake pedals to be adjusted simultaneously forward or rearward. A rocker switch on the instrument panel provides adjustment on the pedals assembly when it is activated. On vehicles with the memory seat option, the pedals position can be controlled by the memory selection, as well as the rocker switch. The accelerator pedal and shaft can still be serviced separately on the adjustable pedals assembly. The components in the acceleration control system are not adjustable and must be replaced if damaged or worn. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Throttle Cable/Linkage: Initial Inspection and Diagnostic Overview 1. Verify the customer's concern by operating the acceleration control system to duplicate the condition. 2. Inspect to determine if any of the mechanical concerns apply: VISUAL INSPECTION CHART Mechanical ^ Damaged accelerator pedal and shaft ^ Damaged linkage ^ Damaged accelerator cable ^ High engine idle speed ^ Damaged throttle body ^ Damaged or binding adjustable pedal assembly 3. If the inspection reveals an obvious concern that can be readily identified, repair it as required. 4. If the concern remains after the inspection, determine the symptom(s) and go to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4786 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable Throttle Cable/Linkage: Service and Repair Cable REMOVAL 1. Disconnect the accelerator cable from the accelerator pedal and shaft. 2. Remove the left hand side accelerator control splash shield bolts. 3. Remove the right hand side splash shield bolt and remove the splash shield. 4. Remove the accelerator cable clip. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable > Page 4789 5. Squeeze the accelerator cable lock tabs on the inside of the passenger compartment and push the accelerator cable into the engine compartment. 6. Depress the locking tabs and remove the accelerator cable from the accelerator cable bracket. 7. Disconnect the accelerator cable from the throttle lever. 1 Rotate the throttle lever forward. 2 Disconnect the accelerator cable from the throttle lever. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable > Page 4790 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable > Page 4791 Throttle Cable/Linkage: Service and Repair Cable Bracket REMOVAL 1. Remove the left hand side accelerator control splash shield bolts. 2. Remove the right hand side accelerator control splash shield bolt and remove the splash shield. 3. Disconnect the speed control cable. Refer to Cruise Control. 4. Disconnect the accelerator cable from the throttle lever. 1 Rotate the throttle lever forward. ^ Slide the accelerator cable end from the throttle lever. 5. Depress the locking tabs and remove the accelerator cable from the accelerator cable bracket. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable > Page 4792 6. Remove the spring from the accelerator cable bracket. 7. Remove the bolts and remove the accelerator cable bracket. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Cable > Page 4793 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > General Throttle Position Sensor: Description and Operation General The TP sensor: ^ sends the PCM a signal indicating the throttle plate angle. ^ is the main input to the PCM from the driver. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > General > Page 4799 Throttle Position Sensor: Description and Operation Throttle Position Sensor Throttle Position Sensor Throttle Position (TP) Sensor The Throttle Position (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 three-blade electrical connector that may be gold plated. The gold plating increases corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are determined by the PCM from the TP. Those conditions are closed throttle (includes idle or deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes maximum acceleration or de-choke on crank), and throttle angle rate. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 4800 Throttle Position Sensor: Service and Repair REMOVAL 1. Remove the bolts and the accelerator splash shield. 2. Disconnect the Throttle Position (TP) sensor electrical connector. 3. Remove the screws and the TP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Manifold Runner Control <--> [Variable Induction System] > Variable Induction Control Valve > Component Information > Description and Operation Variable Induction Control Valve: Description and Operation Intake Manifold Tuning (IMT) Valve Intake Manifold Tuning Valve (IMTV) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Manifold Runner Control <--> [Variable Induction System] > Variable Induction Control Valve > Component Information > Description and Operation > Page 4805 Intake Air System Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Manifold Runner Control <--> [Variable Induction System] > Variable Induction Control Valve > Component Information > Description and Operation > Page 4806 2.5L Cougar Intake Air System 3.0L LS6 Intake Air System Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Manifold Runner Control <--> [Variable Induction System] > Variable Induction Control Valve > Component Information > Description and Operation > Page 4807 3.8L Windstar Intake Air System Intake Air System Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Manifold Runner Control <--> [Variable Induction System] > Variable Induction Control Valve > Component Information > Description and Operation > Page 4808 4.6L E/F-Series Intake Air System 5.4L (4V) Intake Air System The Intake Manifold Tuning (IMT) valve is a motorized actuated unit mounted directly to the intake manifold. The IMT valve 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. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Manifold Runner Control <--> [Variable Induction System] > Variable Induction Control Valve > Component Information > Description and Operation > Page 4809 The IMT valve motorized unit will not be energized below approximately 2600 rpm or higher on some vehicles. The shutter will be in the closed position not allowing airflow blend to occur in the intake manifold. Above approximately 2600 rpm or higher, the motorized unit will be energized. The motorized unit will be 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. 1. The PCM uses the TP sensor and CKP signals to determine activation of the IMT valve system. There must be a positive change in voltage from the TP sensor along with the increase in rpm to open the shutter. 2. The PCM uses the information from the input signals to control the IMT valve. 3. When commanded on by the PCM, the motorized actuator shutter opens up the end of the vertical separating wall at high engine speeds to allow both sides of the manifold to blend together. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications V8 Firing Order: 1 3 7 2 6 5 4 8 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Page 4814 Firing Order: Locations V8 Firing Order: 1 3 7 2 6 5 4 8 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft position sensor bolt 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4822 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > General Camshaft Position Sensor: Description and Operation General The CMP sensor: ^ sends the PCM a signal indicating camshaft position used for fuel synchronization. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > General > Page 4825 Camshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 4826 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft position sensor bolt 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4830 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (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 Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 4833 Crankshaft Position Sensor: Description and Operation Engine Ignition The CKP sensor: ^ is a variable reluctance sensor. ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. ^ provides base timing and crankshaft speed (rpm) to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 4834 Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 4835 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the A/C compressor. For additional information, refer to Heating and Air Conditioning. 2. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips Ignition Coil: Technical Service Bulletins Ignition System - Coil-On-Plug Misfire Diagnostic Tips TSB 05-22-8 11/14/05 WDS COP KIT DIAGNOSTIC TIPS - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING FORD: 1996-1999 Taurus SHO 1998-2006 Crown Victoria, Mustang 2000 Taurus 2002-2005 Thunderbird 2003-2006 Focus 2004-2006 Taurus 2005-2006 Five Hundred, Freestyle 1997-2006 E-Series, Expedition, F-150 1999-2006 F-Super Duty 2000-2005 Excursion, F-53 2001-2006 Escape 2002-2005 Explorer 2005-2006 Escape Hybrid LINCOLN: 1997-1998 Mark VIII 1998-2002 Continental 1998-2006 Town Car 2000-2006 LS 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 1998-2006 Grand Marquis 2000 Sable 2004-2005 Sable 2005-2006 Montego 2002-2005 Mountaineer 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 04-16-01 to update the vehicle applications and model years. NOTE FOLLOW THIS TSB PROCEDURE ONLY IF THERE ARE NO SPECIFIC MISFIRE TSBs/SSMs RELEASED FOR THE VEHICLE SYMPTOM BEING EXPERIENCED. ISSUE Approximately 50% of coil on plug (COP) coils returned for warranty do not have a problem. ACTION The misfiring cylinder must be identified through Self-Test misfire codes or through WDS Power Balance. Rule out base engine problems, rule out fuel problems, and then look at ignition problems (be sure to rule out coil primary circuit issues). Once the above steps have been completed, and the issue is in the secondary part of the ignition system, the oscilloscope procedure outlined in this TSB can isolate the difference between a coil or spark plug problem. SERVICE PROCEDURE The optional WDS COP Kit available through Rotunda will provide more accurate diagnosis and help reduce replacement of non-defective parts. The Kit (418-F5528) can be purchased through 1-800-ROTUNDA. The following material will detail the diagnostic steps on WDS to take the guesswork out of misfire diagnosis using the COP Kit. The following Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4840 procedure is for cylinder specific misfires and not random misfires. Random misfires have a different root cause and are not covered by this TSB. Misfire Definition: A misfiring cylinder is lacking power relative to the other cylinders. The causes for a cylinder specific misfire could be fuel, spark, or mechanical problems. Perform a thorough visual inspection. If no visible concerns are found use the following WDS tools for misfire diagnosis: ^ Self-test (Check for codes first) Power Balance (Identify the cylinder of concern) ^ Relative Compression (Rule out a possible mechanical issue) ^ Fuel (Make sure fuel injectors are not restricted) ^ Ignition (Make sure spark plugs and coils are working properly) ^ Oscilloscope (Detailed signal analysis) NOTE USE THE ENCYCLOPEDIA BUTTON IN THE LOWER LEFT CORNER OF THE SCREEN FOR DETAILED INFORMATION ON THE WDS TOOL BEING DISPLAYED. If there is a self-test code identifying a particular cylinder then you just need to determine if it is a fuel, ignition, or possibly a mechanical problem. Proceed to Step 2 after running Relative Compression to rule out any mechanical issues. If there is no self-test code and the customer concern is a miss, proceed to Step 1. Step 1: (Select Toolbox Icon, then Powertrain, then Power Balance) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4841 The cylinder specific miss has to be identified as shown in the example in Figure 2 in order to proceed with the remaining steps. If the miss does not occur at idle (in the bay), try to brake torque the engine. This extra loading should reproduce the miss in the bay. If the miss cannot be reproduced during brake torque, select Relative Compression under Powertrain on WDS before going on a road test to rule out mechanical problems. If Relative Compression shows a problem then the base engine issue must be serviced. If Relative Compression results are good (Figure 3), road test under as many different driving conditions as possible until the miss occurs on Power Balance. Some misses may be very intermiffent so be patient and concentrate on steady load conditions. Once a cylinder dropout is identified proceed to Step 2. Step 2: (Select Toolbox Icon, then Powertrain, then Fuel System Test) Run Fuel System Test on WDS to determine if there may be a fuel problem. After completing fuel Pressure/Leakdown test, select Injector flow to isolate Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4842 a restricted injector as shown in Figure 4. If all the injectors are within specification, proceed to Step 3. Step 3: (Select Toolbox Icon, then Powertrain, then Ignition System Test) Run Ignition System Test on WDS to determine if there is an ignition problem. Look at both duration (DUR) and kilovolts (KV) and look for values that standout from the rest as shown in Figure 5 and Figure 6. NOTE LIVE DISPLAY HAS TO AVERAGE IGNITION VALUES BECAUSE THERE IS TOO MUCH DATA TO DISPLAY. MAKE A CAPTURE TO VIEW EACH ENGINE EVENT WITHOUT AVERAGING. THIS CAN BE HELPFUL WHEN THE PROBLEM IS INTERMITTENT. IF THE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4843 MISS IS EXTREMELY INTERMITTENT AND DOES NOT SHOW UP IN IGNITION, PROCEED TO STEP 4. If either spark duration or peak KV on the Red Probe (Suspect Cylinder) are offset from the values displayed on the Black Probe (Known Good Cylinder) then the problem is in the ignition system. Rule out coil primary circuit issues before proceeding to coil secondary issues such as the spark plug , coil boot, or possibly the coil. Use the WDS Oscilloscope with the COP kit to determine if the issue is the coil or the spark plug. Step 4: (Select Toolbox, then Oscilloscope) WARNING SECONDARY IGNITION VOLTAGES ARE VERY HIGH. KEEP HANDS AND TOOLS AWAY FROM THE END OF THE COIL THAT SUPPLIES THE SPARK. SET-UP: With the engine off, pull the suspect coil from the cylinder well and turn it upside down so the coil cannot spark to any other surface as shown in Figure 1. Wrap a clean shop cloth around the hard shell of the coil to help keep the coil propped up and stable. CAUTION THE COIL BOOT CAN BE DAMAGED IF THE COIL SPARKS TO ANOTHER SURFACE DURING THIS PROCEDURE. Keep the coil connected to the harness and leave the WDS COP clip attached to the coil. Route the coil clip wire and cable away from the coil being tested as well as other coils to avoid noise interference. Disconnect the injector of the cylinder being tested so raw fuel is not washing the cylinder. This is a stress test for the coil. The type of waveform displayed on the oscilloscope will show whether a coil or the plug is the problem if all previous steps have been followed. Keep hands and tools away from the end of the coil that supplies the spark. COP Stress Test Procedure: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4844 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 4845 Go to the Oscilloscope Tool and select Channel 3, then select Auto, then select COP_STRESS_TEST_RED. This pre-configured setting will zoom-in on the peak firing of the coil being tested. Start the engine and be sure the coil is not sparking to any surface. If the coil is sparking to other surfaces, turn the engine off immediately and readjust the coil so it cannot spark to any other surface. Restart the engine and touch the Red Man icon to start the oscilloscope. All settings are pre-configured and no adjustments are necessary. Compare the waveform you get with the examples provided in Figures 7, 8, and 9). Figure 7 is a good waveform. If your waveform is similar to Figure 7 the coil is working correctly. Suspect the spark plug. Figure 8 and Figure 9 are examples of problem coils. Replace the coil if the waveform is similar to Figures 8 or 9. The coil is causing the misfire when the peak firing appears like those shown in Figures 8 and 9. Notice the difference in the peak-firing signal when compared to the good peak signal in Figure 7. Figure 9 shows a more dramatic fault in the peak failure. Most root causes of misfire issues can be identified quickly using the steps outlined above. Some misfire issues can be difficult making the oscilloscope an important part of your diagnostic toolbox. OTHER APPLICABLE ARTICLES: 05-13-4 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Mechanical Specifications Ignition Coil: Mechanical Specifications Ignition coil 40 - 61 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 4848 Ignition Coil: Description and Operation The eight separate ignition coils: ^ change low voltage signals from the PCM to high voltage pulses ^ produce the high voltage pulses to the spark plugs. ^ are connected directly to each spark plug. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 4849 Ignition Coil: Service and Repair REMOVAL 1. Disconnect the Coil On Plug (COP) electrical connectors. 2. Remove the bolts. 3. Remove the coil on plugs. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A meeting Ford specification ESE-M1C171-A or equivalent to the inside of the coil boots. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock sensor 13 - 16 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > General Knock Sensor: Description and Operation General The system has a unique linear KS located in the lifter valley. ^ The KS sends a signal to the PCM indicating engine detonation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > General > Page 4855 Knock Sensor: Description and Operation Knock Sensor Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > Page 4856 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. For additional information, refer to Engine. 2. Remove the Knock Sensor (KS). 1 Disconnect the electrical connector. 2 Remove the nut and the KS. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications Camshaft Position Sensor: Specifications Camshaft position sensor bolt 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4861 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > General Camshaft Position Sensor: Description and Operation General The CMP sensor: ^ sends the PCM a signal indicating camshaft position used for fuel synchronization. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > General > Page 4864 Camshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Camshaft Position Sensor The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No. 1 is on its compression stroke. A signal is then sent to the Powertrain Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. Typical Hall-Effect Sensor Typical Variable Reluctant Sensor There are two types of CMP sensors: the three pin connector Hall-effect type sensor and the two pin connector variable reluctance sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 4865 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft position sensor bolt 71 - 106 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4869 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor: Description and Operation 2000 All (Except diesel/Propane/Villager) Crankshaft Position Sensor (Integrated Ignition Systems) Three Different Types Of Crankshaft Position (CKP) Sensors The Crankshaft Position (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 Powertrain Control Module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 4872 Crankshaft Position Sensor: Description and Operation Engine Ignition The CKP sensor: ^ is a variable reluctance sensor. ^ is triggered by a 36-minus-1 tooth trigger wheel mounted on the crankshaft. ^ provides base timing and crankshaft speed (rpm) to the Powertrain Control Module (PCM). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > 2000 All (Except diesel/Propane/Villager) > Page 4873 Crankshaft Position Sensor: Description and Operation Electronic Engine Controls The CKP sensor: ^ sends the PCM a signal indicating crankshaft position. ^ is essential for calculating spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page 4874 Crankshaft Position Sensor: Service and Repair REMOVAL 1. Remove the A/C compressor. For additional information, refer to Heating and Air Conditioning. 2. Remove the Crankshaft Position (CKP) sensor. 1 Disconnect the electrical connector. 2 Remove the bolt and the sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4880 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4881 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4882 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4883 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 4884 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Knock sensor 13 - 16 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > General Knock Sensor: Description and Operation General The system has a unique linear KS located in the lifter valley. ^ The KS sends a signal to the PCM indicating engine detonation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > General > Page 4890 Knock Sensor: Description and Operation Knock Sensor Knock Sensor Knock Sensor (KS) The Knock Sensor (KS) is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Page 4891 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. For additional information, refer to Engine. 2. Remove the Knock Sensor (KS). 1 Disconnect the electrical connector. 2 Remove the nut and the KS. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plugs 9-20 Nm Original Spark Plug AWSF22E Replacement Spark Plug AWSF22E Spark Plug Gap 1.32-1.42 mm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 4896 Spark Plug: Specifications Spark Plugs 9-20 Nm Original Spark Plug AWSF22E Replacement Spark Plug AWSF22E Spark Plug Gap 1.32-1.42 mm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4897 Spark Plug: Application and ID Original Spark Plug Type ..................................................................................................................... ............................................................... AWSF22E Replacement Spark Plug Type .......................... ................................................................................................................................................... AWSF22E Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4898 Spark Plug: Description and Operation The spark plugs: ^ change a high voltage pulse into a spark which ignites the fuel and air mixture. ^ originally equipped on the vehicle have a platinum-enhanced electrode for long life. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Removal and Installation Spark Plug: Service and Repair Removal and Installation SPARK PLUG Engine Ignition - RH Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Removal and Installation > Page 4901 Engine Ignition - LH Exploded View Material Removal and Installation See TSB 8-1-9 Jan. 2008 1. Disconnect the ignition coil electrical connector. 2. NOTE: When removing the ignition coils, a slight twisting motion will break the seal and ease removal. Remove the bolt and the ignition coil. 3. NOTICE: Do not remove the spark plugs when the engine is hot or cold soaked. Spark plug thread or cylinder head damage can occur. Make sure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Removal and Installation > Page 4902 the engine is warm (hand touch after cooling down) prior to spark plug removal. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs. Remove the spark plug in the following sequence. (1).Loosen the spark plug no more than one-eighth to one-fourth of a turn. (2).NOTICE: Excessive use of carburetor tune-up cleaner can introduce enough liquid volume to hydro-lock the engine. Using carburetor tune-up cleaner, fill the spark plug well until fluid has reached the spark plug jamb nut. Follow the directions on the packaging. (3).NOTICE: Do not loosen or tighten the spark plug for a minimum of 15 minutes or damage to the cylinder head or spark plug may occur. Let the carburetor tune-up cleaner soak for a minimum of 15 minutes. (4).NOTE: Some screeching and high effort may be noticed and is normal. NOTE: The expected removal torque is around 45 Nm (33 lb-ft). Tighten, and then loosen the spark plug, repeating until turning effort is reduced, and remove the spark plug. 4. Inspect the spark plug. Install a new spark plug as necessary. Installation 1. NOTICE: The spark plug gap is NOT adjustable. Damage can occur to the ceramic if the spark plug gap is adjusted. Install a new spark plug if the gap is out of specification. NOTE: Refer to the specifications in this section for correct spark plug identification. NOTE: Do not apply high temperature nickel anti-seize lubricant to the spark plug ground strap area. Apply high temperature nickel anti-seize lubricant to only the spark plug ground electrode shield as shown. 2. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug. Install the spark plug. To install, tighten to 34 Nm (25 lb-ft). 3. NOTE: Verify that the ignition coil spring is correctly located inside the ignition coil-on-plug boot and that there is no damage to the tip of the boot. Install the ignition coil and the bolt. Apply a light coat of dielectric compound to the inside of the ignition coil boots. To install, tighten to 6 Nm (53 lb-in). 4. Connect the ignition coil electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Removal and Installation > Page 4903 Spark Plug: Service and Repair Spark Plug - Inspection REMOVAL 1. Remove the coil on plugs. For additional information refer to Ignition Coil. 2. Remove the spark plugs. NOTE: Remove any foreign material from the spark plug wells with compressed air before removing the spark plugs. 3. Inspect the spark plugs. For additional information, refer to Engine. 4. Adjust the spark plug gap as necessary. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications Shift Lock Actuator: Specifications Shift Lock Actuator Bolts 62.5 - 98 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications > Page 4910 Shift Lock Actuator: Service and Repair Removal 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. 1 Remove the bolts. 2 Remove the insert plate and shift lock actuator. 3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications Shift Motor Bolts .................................................................................................................................. ................................................. 10 Nm (89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 4915 Transfer Case Actuator: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the coil wire pin from the electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire pin. - Use proper electrical connector pin remover. 4. CAUTION: Note each sensor wire pin location for correct installation. Remove the front and rear output shaft speed sensor wire pins from the electrical connector. Use the proper electrical connector pin remover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 4916 5. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission control selector lever in the (D) position. - Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D) position). 3. Hang an eight pound weight on the transmission control selector lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the shift control selector lever from detent to detent and compare with transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 4931 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 4937 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 4948 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 4949 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts Control Module: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts > Page 4955 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts > Page 4956 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 4959 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 4960 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 4961 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 4962 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 4963 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 4964 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 4965 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 4966 Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 4967 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 4968 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 4969 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 4970 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 4971 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 4972 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque on Demand Relay Four Wheel Drive Selector Relay: Locations Torque on Demand Relay The Torque on Demand relay is located behind the center of the Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque on Demand Relay > Page 4977 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay The Torque on Demand relay is located behind the center of the Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque on Demand Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque on Demand Relay > Page 4980 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation Transmission Control Switch Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 4986 Transmission Mode Switch: Service and Repair Removal 1. Remove the Transmission Control (TC) switch. 1 Remove the TC switch cover. 2 Remove the TC switch. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission TR Sensor 71 - 88 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4990 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > 4R70W Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > 4R70W > Page 4993 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 4994 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 4995 Digital Transmission Range Sensor: Service and Repair Special Tools Removal 1. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If this concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 4996 5. Remove the digital Transmission Range (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. Installation 1. Install the digital Transmission Range (TR) sensor. 1 Install digital Transmission Range (TR) sensor. 2 Loosely install the bolts. 2. Note: Make sure that the manual control lever is in the neutral position. Install the TRS Alignment Gauge. The TRS Alignment Gauge is designed to fit snug. 3. Tighten the bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 4997 4. Reconnect the shift cable at the manual control lever. 5. Reconnect the connector. 6. Lower the vehicle. 7. Reconnect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 71 - 88 in.lb Turbine Shaft Speed (TSS) Sensor Bolt 71 - 88 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5001 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Output Shaft Speed (OSS) Sensor > Page 5004 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5005 Transmission Speed Sensor: Service and Repair Removal 1. Remove the drive shaft. 2. Remove the rear transmission mount nuts. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Remove the rear transmission mount. 1 Raise the transmission up off the rear crossmember support. 2 Remove the bolts. 3 Remove the rear transmission mount. 4. Lower the transmission to gain access to the Turbine Shaft Speed (TSS) sensor, and the Output Shaft Speed (OSS) sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5006 5. Remove the Turbine Shaft Sensor (TSS). 1 Remove the bolt. 2 Remove the Turbine Shaft Sensor (TSS). 6. Remove the Output Shaft Speed (OSS) sensor. 1 Remove the bolt. 2 Remove the Output Shaft Speed (OSS) sensor. Installation 1. Install the Output Shaft Speed (OSS) sensor. 1 Lubricate the O-ring and install the Output Shaft Speed (OSS) sensor. 2 Install the bolt. 2. Install the Turbine Shaft Sensor (TSS). 1 Lubricate the O-ring and install the Turbine Shaft Sensor (TSS). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5007 2 Install the bolt. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the sensors will occur. Install the rear transmission mount. 1 Raise the transmission up. 2 Install the rear transmission mount. 3 Install the bolts. 4. Lower the transmission on to the rear crossmember support. 5. Install the rear transmission mount nuts. 6. Install the drive shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 5012 Four Wheel Drive Selector Switch: Description and Operation 4x4 Mode Switch Typical 4x4 Switch The Generic Electronic Module (GEM) provides the PCM with an indication of 4x4L. This input is used to adjust the shift schedule. A 5.0 volt module pull-up indicates 4x4H or 4x2. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 5013 Four Wheel Drive Selector Switch: Service and Repair Removal 1. Remove the center instrument panel trim panel. 2. Remove the shift range selector switch. 1 Remove the switch knob. 2 Disconnect the electrical connector. 3 Remove the bolts. 4 Remove the shift range selector switch. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications Output Speed Sensor Bolt 44 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Front Output Shaft Speed Sensor Speed Sensor: Service and Repair Front Output Shaft Speed Sensor Removal 1. Remove the transfer case shift motor. 2. Remove the wire connector spacer and the front output shaft speed sensor wire pins from the electrical connector. - Use the proper electrical connector pin remover. 3. Remove the front output shaft speed sensor. 1 Remove the bolt. 2 Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats net against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Front Output Shaft Speed Sensor > Page 5019 Speed Sensor: Service and Repair Rear Output Shaft Speed Sensor Removal WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air spring, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the wire connector spacer and the rear output shaft speed sensor wire pins from the electrical connector. - Use the proper electrical connector pin remover. 4. Remove the bolt, and remove the sensor. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Front Output Shaft Speed Sensor > Page 5020 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 02-12-3 > Jun > 02 > Engine - Lacks Power in High Temperatures PROM - Programmable Read Only Memory: Customer Interest Engine - Lacks Power in High Temperatures Article No. 02-12-3 06/24/02 ^ DRIVEABILITY - ENGINE LACKS POWER WHEN OPERATING IN HIGH AMBIENT TEMPERATURES ABOVE 38C (100F) - VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY ^ ENGINE - 5.4L - ENGINE LACKS POWER WHEN OPERATING IN HIGH AMBIENT TEMPERATURES ABOVE 38C (100F) FORD: 2000-2002 EXPEDITION, F-150 ISSUE Some vehicles equipped with the 5.4L-2V engine may exhibit a lack of power condition when operating in ambient temperatures above 38°C (100 °F). This may be caused by the Powertrain Control Module (PCM) calibration which retards the ignition timing to prevent detonation when the Inlet Air Temperature (IAT) reaches 60°C (140 °F) or above. This may be more pronounced during stop-and-go driving. ACTION Verify the condition. Reprogram the PCM with the latest calibration and on 2000 and 2001 F-150's, install body plugs behind Coolant Overflow Bottle if missing. Refer to the following Service Procedure for details. SERVICE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 02-12-3 > Jun > 02 > Engine - Lacks Power in High Temperatures > Page 5029 For 2000-2002 F-150's and Expeditions equipped with a 5.4L 2V engine, if a lack of power occurs only when the IAT is above 60°C (140°F), reprogram the PCM to the latest level calibration as shown. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 02-12-3 > Jun > 02 > Engine - Lacks Power in High Temperatures > Page 5030 For 2000 and 2001 F150's, install Body Plugs (383181-S and N807093-S) behind the Coolant Overflow Bottle. Refer to Figure 1 for location and plug button installation. These plugs will reduce the engine compartment heat moving into the air cleaner inlet area. Body Plug Installation 1. Remove air cleaner inlet. Refer to Section 303-12. 2. Remove jack handle. 3. Remove upper radiator sight shield. 4. Disconnect radiator overflow hose from radiator to degas bottle. 5. Position degas bottle away from body plug hole area. 6. Install body plugs in location shown in illustration. 7. Position back degas bottle Torque to 9 N.m (80 Lb-in). 8. Connect radiator overflow hose. 9. Install upper radiator sight shield. 10. Install jack handle. 11. Install air cleaner inlet. Refer to Section 303-12. Parts Block Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 02-12-3 > Jun > 02 > Engine - Lacks Power in High Temperatures > Page 5031 Obtain an Authorized Modifications Decal (FPS 8262 obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 021203A Reprogram Powertrain 0.6 Hr. Control Module: 2000, 2001, 2002, F-150, F-150 Super Crew, Expedition 021203B Reprogram Powertrain 0.9 Hr. Control Module And Install Body Plugs If Missing: 2000, 2001 F-150, F-150 Super Crew DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 42 OASIS CODES: 614000, 614500, 614600, 622000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set PROM - Programmable Read Only Memory: Customer Interest PCM - MIL ON, DTC's P0350/P0360 Set Article No. 01-1-6 01/22/01 ^ DIAGNOSTIC TROUBLE CODES (DTCS) - P0350-P0360 COIL DTCS STORED IN MEMORY ROUGH IDLE - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - COIL ON PLUG APPLICATIONS ONLY ^ MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - ROUGH IDLE - DIAGNOSTIC TROUBLE CODES (DTCS) P0350-P0360 COIL DTCS STORED IN MEMORY - COIL ON PLUG APPLICATIONS ONLY ^ ROUGH IDLE - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0350-P0360 COIL DTCS STORED IN MEMORY ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - ROUGH IDLE DIAGNOSTIC TROUBLE CODES (DTCS) P0350-P0360 COIL DTCS STORED IN MEMORY COIL ON PLUG APPLICATIONS ONLY FORD: 2000 CROWN VICTORIA, ECONOLINE, EXCURSION, EXPEDITION, F SUPER DUTY, F-150 LINCOLN: 2000 LS, TOWN CAR, NAVIGATOR MERCURY: 2000 GRAND MARQUIS ISSUE Some 2000 Coil-On-Plug applications may produce P0350 through P0360 coil Diagnostic Trouble Codes (DTCS), a check engine light, and rough idle. This may be caused by the Powertrain Control Module (PCM) calibration. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 5036 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 5037 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 5038 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 5039 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 5040 ACTION Perform normal diagnostics. If normal diagnostics cannot pinpoint the condition and no other concerns are found, reprogram the PCM using the Worldwide Diagnostic System (WDS) or New Generation Star (NGS) Tester. Refer to the PCM Calibration Information Chart as shown. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage DEALER CODING Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 5041 OASIS CODES: 206000, 608000, 608400, 609000, 609400, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5047 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5048 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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: > 02-12-3 > Jun > 02 > Engine - Lacks Power in High Temperatures PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine - Lacks Power in High Temperatures Article No. 02-12-3 06/24/02 ^ DRIVEABILITY - ENGINE LACKS POWER WHEN OPERATING IN HIGH AMBIENT TEMPERATURES ABOVE 38C (100F) - VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY ^ ENGINE - 5.4L - ENGINE LACKS POWER WHEN OPERATING IN HIGH AMBIENT TEMPERATURES ABOVE 38C (100F) FORD: 2000-2002 EXPEDITION, F-150 ISSUE Some vehicles equipped with the 5.4L-2V engine may exhibit a lack of power condition when operating in ambient temperatures above 38°C (100 °F). This may be caused by the Powertrain Control Module (PCM) calibration which retards the ignition timing to prevent detonation when the Inlet Air Temperature (IAT) reaches 60°C (140 °F) or above. This may be more pronounced during stop-and-go driving. ACTION Verify the condition. Reprogram the PCM with the latest calibration and on 2000 and 2001 F-150's, install body plugs behind Coolant Overflow Bottle if missing. Refer to the following Service Procedure for details. SERVICE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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: > 02-12-3 > Jun > 02 > Engine - Lacks Power in High Temperatures > Page 5053 For 2000-2002 F-150's and Expeditions equipped with a 5.4L 2V engine, if a lack of power occurs only when the IAT is above 60°C (140°F), reprogram the PCM to the latest level calibration as shown. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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: > 02-12-3 > Jun > 02 > Engine - Lacks Power in High Temperatures > Page 5054 For 2000 and 2001 F150's, install Body Plugs (383181-S and N807093-S) behind the Coolant Overflow Bottle. Refer to Figure 1 for location and plug button installation. These plugs will reduce the engine compartment heat moving into the air cleaner inlet area. Body Plug Installation 1. Remove air cleaner inlet. Refer to Section 303-12. 2. Remove jack handle. 3. Remove upper radiator sight shield. 4. Disconnect radiator overflow hose from radiator to degas bottle. 5. Position degas bottle away from body plug hole area. 6. Install body plugs in location shown in illustration. 7. Position back degas bottle Torque to 9 N.m (80 Lb-in). 8. Connect radiator overflow hose. 9. Install upper radiator sight shield. 10. Install jack handle. 11. Install air cleaner inlet. Refer to Section 303-12. Parts Block Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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: > 02-12-3 > Jun > 02 > Engine - Lacks Power in High Temperatures > Page 5055 Obtain an Authorized Modifications Decal (FPS 8262 obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 021203A Reprogram Powertrain 0.6 Hr. Control Module: 2000, 2001, 2002, F-150, F-150 Super Crew, Expedition 021203B Reprogram Powertrain 0.9 Hr. Control Module And Install Body Plugs If Missing: 2000, 2001 F-150, F-150 Super Crew DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 42 OASIS CODES: 614000, 614500, 614600, 622000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - MIL ON, DTC's P0350/P0360 Set Article No. 01-1-6 01/22/01 ^ DIAGNOSTIC TROUBLE CODES (DTCS) - P0350-P0360 COIL DTCS STORED IN MEMORY ROUGH IDLE - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - COIL ON PLUG APPLICATIONS ONLY ^ MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - ROUGH IDLE - DIAGNOSTIC TROUBLE CODES (DTCS) P0350-P0360 COIL DTCS STORED IN MEMORY - COIL ON PLUG APPLICATIONS ONLY ^ ROUGH IDLE - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTCS) P0350-P0360 COIL DTCS STORED IN MEMORY ^ LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - ROUGH IDLE DIAGNOSTIC TROUBLE CODES (DTCS) P0350-P0360 COIL DTCS STORED IN MEMORY COIL ON PLUG APPLICATIONS ONLY FORD: 2000 CROWN VICTORIA, ECONOLINE, EXCURSION, EXPEDITION, F SUPER DUTY, F-150 LINCOLN: 2000 LS, TOWN CAR, NAVIGATOR MERCURY: 2000 GRAND MARQUIS ISSUE Some 2000 Coil-On-Plug applications may produce P0350 through P0360 coil Diagnostic Trouble Codes (DTCS), a check engine light, and rough idle. This may be caused by the Powertrain Control Module (PCM) calibration. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 5060 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 5061 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 5062 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 5063 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 5064 ACTION Perform normal diagnostics. If normal diagnostics cannot pinpoint the condition and no other concerns are found, reprogram the PCM using the Worldwide Diagnostic System (WDS) or New Generation Star (NGS) Tester. Refer to the PCM Calibration Information Chart as shown. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage DEALER CODING Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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: > 01-1-6 > Jan > 01 > PCM - MIL ON, DTC's P0350/P0360 Set > Page 5065 OASIS CODES: 206000, 608000, 608400, 609000, 609400, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5071 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5072 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications Shift Lock Actuator: Specifications Shift Lock Actuator Bolts 62.5 - 98 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications > Page 5079 Shift Lock Actuator: Service and Repair Removal 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. 1 Remove the bolts. 2 Remove the insert plate and shift lock actuator. 3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications Shift Motor Bolts .................................................................................................................................. ................................................. 10 Nm (89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5084 Transfer Case Actuator: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the coil wire pin from the electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire pin. - Use proper electrical connector pin remover. 4. CAUTION: Note each sensor wire pin location for correct installation. Remove the front and rear output shaft speed sensor wire pins from the electrical connector. Use the proper electrical connector pin remover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5085 5. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications Shift Lock Actuator: Specifications Shift Lock Actuator Bolts 62.5 - 98 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications > Page 5091 Shift Lock Actuator: Service and Repair Removal 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. 1 Remove the bolts. 2 Remove the insert plate and shift lock actuator. 3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair Band Apply Servo: Service and Repair Removal 1. Remove the main control valve body. 2. WARNING: The intermediate servo is under spring pressure, care should be taken when removing it. It could cause bodily harm. Note: Gently tap on the servo cover with a rubber mallet to compress and allow servo assembly to pop up. Remove the intermediate servo. Installation 1. Note: Lubricate the servo seal with clean transmission fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Page 5095 Install the intermediate band servo. 2. Install the main control valve body. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Specifications Case: Specifications Extension Housing To Case Bolts 30 - 40 ft.lb Low/Reverse OWC Inner Race To Case 18 - 25 ft.lb Line Pressure To Case Plug 6 - 12 ft.lb Main And Lower Control Body To Case 80 - 97 in.lb Main Accumulator Solenoid Body To Case 80 - 97 in.lb Pump Body To Case 18 - 23 ft.lb Reinforcing Plate To Case Bolts 80 - 97 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications Clutch: Specifications Clearance ............................................................................................................................................ ...................... 1.574-2.159 mm (0.062-0.085 inch) Selective Steel Plates .............................................................................................................................................................. ............. 1.270-1.372 mm (0.050-0.054 inch) ...................................................................................... ..................................................................................... 1.625-1.727 mm (0.064-0.068 inch) .............. ............................................................................................................................................................. 1.981-2.083 mm (0.078-0.082 inch) .................................................................................................... ....................................................................... 2.337-2.438 mm (0.092-0.096 inch) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair Automatic Transmission Dipstick - Dipstick Tube: Service and Repair Removal 1. Remove the fluid level indicator. 2. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If this concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. Raise the vehicle on a hoist. 4. Remove the RH front wheel. 5. Remove the inner wheel liner. 6. Remove the bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair > Page 5105 7. Note: It may be necessary to disconnect the wiring harness from the starter motor to remove the oil filler tube. Remove the oil filler tube. Installation 1. Note: Coat the O-ring at the bottom of the oil filler tube with transmission fluid. If removed, install the starter wiring harness. Install the oil filler tube. 2. Install the bolt. 3. Install the inner wheel liner. 4. Install the RH front wheel. 5. Lower the vehicle. 6. Reconnect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair > Page 5106 7. Install the fluid level indicator. 8. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 5111 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 5112 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 4R100 ................................................................................................................... ........................................................................................................ 15.5L 4R70W .............................. .............................................................................................................................................................. .............................. 13.1L Note: Approximately Dry Fill Capacity Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 5115 Fluid - A/T: Fluid Type Specifications See TSB 06-14-4 Transmission Fluid Type 4R100 .................................................................................................................................................. .................................................................. MERCON 4R70W ............................................................. ................................................................................................................................................. MERCON V MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5116 Fluid - A/T: Service and Repair Removal 1. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If this concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Remove the drain plug to allow the fluid to drain. 4. CAUTION: When replacing the transmission fluid and filter and seal assembly; the torque converter should be drained. Transmission cooler, cooler lines, and cooler bypass valve must be thoroughly flushed to remove any contamination. Note: Do not discard the fluid pan gasket unless damaged. This is a reusable gasket. Remove the transmission fluid pan and gasket. 1 Loosen, but do not remove the bolts. 2 Remove the front and side bolts. 3 Lower the front of the t1uid pan and allow the fluid to drain. 4 Remove the remaking fluid pan bolts and the fluid pan. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5117 5. Note: After removal, discard the filter and seal assembly. Remove the filter and seal assembly by carefully pulling and rotating the filler as necessary. 6. CAUTION: Be careful not to scratch or damage the aluminum bore. The new seal may leak and damage to the case will result. If the seal remains in the pump bore, remove it carefully with a small screwdriver so as not to scratch or damage the aluminum bore. 7. Remove the torque converter drain plug cover. 8. Remove the torque converter drain plug. 9. Note: If equipped with a radiator in-tank transmission fluid cooler, or an auxiliary cooler, the coolers will need to be flushed. Thoroughly flush the cooler lines, fluid coolers, and the cooler bypass valve. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5118 1. After the torque converter has drained, install the drain plug. 2. Install the torque converter drain plug cover. 3. Note: Prior to installation, lightly lubricate the seal with clean MERCON Multipurpose (ATF) Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Press a new fluid filtered seal assembly into the pump bore until seated. 4. CAUTION: Mixing (A) 4x2-style and (B) 4x4-style transmission fluid filters and transmission pan assembly components can cause transmission damage. Install filter assembly and transmission pan. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5119 5. Note: The transmission pan gasket is reusable unless damaged. Note: Apply a light coat of petroleum jelly to hold the gasket to the fluid pan. Position the (A) gasket onto the cleaned fluid pan. Make sure the (B) magnet is positioned over the dimple in the fluid pan. 6. Install the fluid pan. 1 Position the fluid pan. 2 Install the bolts. 7. Lower the vehicle. 8. Reconnect the battery ground cable. 9. CAUTION: Use only MERCON Multipurpose (ATF) Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON. The use of any other fluids can result in the transmission failing to operate in a normal manner or failure. Refill the transmission. Add 6.2 liters (6.5 quarts) of Motorcraft MERCON Multipurpose (ATF) Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON, to the transmission through the fluid filler tube. - Start the engine. Move the transmission range selector lever through all the gear ranges and allow to engage before moving to the next gear. - Check and adjust the transmission fluid, in 0.24 liter (0.5 pint) increments, to the proper level (cross-hatched area of the fluid level Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications Fluid Line/Hose: Specifications Cooler Line Fitting To Case Fitting (Front CBV) 8 - 12 ft.lb Cooler Line Fitting To Case Fitting (Rear CBV) 15 ft.lb Cooler Line Case Fitting (Front CBV) 18 ft.lb Cooler Line Case Fitting (Rear CBV) 22 ft.lb Connector-Radiator Nipple 17 - 23 ft.lb Cooler Line Fitting To Radiator 18 - 22 ft.lb Auxiliary Cooler Tube 8 - 10 ft.lb Auxiliary Cooler Tube 16 - 22 ft.lb Transmission Fluid Cooler Line Fitting 12 - 17.5 ft.lb Front Cooler Bypass Valve (CBV) Bolt 20 - 24 ft.lb Rear Cooler Bypass Valve (CBV) Bolt 25 - 29 ft.lb Transmission Fluid Cooler Tubes (5/16 inch) 21 - 25 ft.lb Transmission Fluid Cooler Tubes (3/8 inch) 18 - 22 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Cooler Bypass Valve Fluid Line/Hose: Service and Repair Cooler Bypass Valve Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Remove the front cooler tube, from the front Cooler Bypass Valve (CBV) fitting. 4. Remove the rear cooler tube from the rear CBV fitting. 5. Note: The rubber-coated sealing washers can fall off during removal of the front CBV bolt cooler line ease fitting. Remove the front CBV bolt cooler ease fitting. 6. Note: The rubber coated sealing washers can fall off during removal of the rear CBV bolt cooler line ease fitting. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Cooler Bypass Valve > Page 5125 Remove the rear CBV bolt cooler line case fitting. 7. Remove, clean and flush the CBV. Installation 1. CAUTION: Make sure the 4 rubber-coated sealing washers are on the cooler line case fittings and the CBV washers are in place. Examine the rubber-coated sealing washers for damage. Replace the washers as needed. 2. Using Threadlock and Sealer E0AZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5, coat the line case fitting threads. 3. CAUTION: Make sure the Cooler Bypass Valve (CBV) is properly backflushed. Use dry compressed air to remove solvent. CAUTION: If the cooler line case fitting is overtightened, the rubber-coated sealing washers and/or cooler line case fittings can be damaged, causing a transmission fluid leak. Note: The CBV has a check ball in the rear fitting and will only allow flow in one direction. Make sure check ball moves freely. Note: Align the two rubber-coated sealing washers while assembling the rear cooler line case fitting. Install the CBV fitting. 4. Note: The cooler lines need to be flushed out at this time. Tighten the cooler tube nuts. 5. Lower the vehicle. - Reconnect the battery ground cable. 7. Fill the transmission with Motorcraft MERCON Multipurpose (ATF) Transmission Fluid XT-2-QDX or equivalent meeting MERCON specification. Check for proper operation. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Cooler Bypass Valve > Page 5126 Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Tubes Removal 1. Shut off air suspension, if equipped. 2. Raise and support the vehicle. 3. Remove the front skid plate. 1 Remove the bolts. 2 Remove the front skid plate. 4. Remove the lower air deflector. 1 Remove the bolts. 2 Remove the lower air dam. 5. Note: Note the differences in the tube routing between (A) vehicles with a transmission auxiliary fluid cooler and (B) vehicles without an Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Cooler Bypass Valve > Page 5127 auxiliary fluid cooler. For 4R70W transmission-equipped vehicles, remove the transmission fluid cooler tube. 1 Remove the clips. 2 Disconnect the tube fittings. 3 Remove the transmission fluid cooler tube 6. Note: Note the differences in the tube routing between (A) vehicles with a transmission auxiliary fluid cooler and (B) vehicles without an auxiliary fluid cooler. For 4R100 transmission-equipped vehicles, remove the transmission fluid cooler tube. 1 Remove the clips. 2 Disconnect the tube fittings. 3 Remove the transmission fluid cooler tube. Installation 1. Note: Note the differences in the tube routing between the vehicles with a transmission auxiliary fluid cooler and the vehicles without an auxiliary fluid cooler. Install the transmission fluid cooler tube. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Cooler Bypass Valve > Page 5128 1 Position the transmission fluid cooler tube 2 Connect the tube fittings. 3 Install the clips. 2. On 4R100 transmission-equipped vehicles, connect the transmission fluid cooler tubes to the cooler bypass valve. 3. Install the lower air deflector. 1 Position the lower air dam. 2 Install the bolts. 4. Install the front skid plate. - Install the bolts. 5. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 6. Fill the transmission fluid to the proper level and inspect for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Transmission Pan 10 - 12 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications Control Assembly To Pump Body Bolts 18 - 23 ft.lb Stator To Support To Pump Body Bolts 20 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission control selector lever in the (D) position. - Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D) position). 3. Hang an eight pound weight on the transmission control selector lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the shift control selector lever from detent to detent and compare with transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift Planetary Gears: Customer Interest A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Article No. 01-13-7 07/09/01 ^ NOISE - "CLUNK" NOISE HEARD ON 2-1 DOWNSHIFT VEHICLES EQUIPPED WITH 4R70W AUTOMATIC TRANSMISSION ^ TRANSMISSION - 4R70W - "CLUNK" NOISE HEARD FROM TRANSMISSION ON 2-1 DOWNSHIFT FORD: 1999-2001 CROWN VICTORIA, MUSTANG 1999 F-250 LD 1999-2001 E SERIES, EXPEDITION, EXPLORER, F-150 LINCOLN: 1999-2001 TOWN CAR MERCURY: 1999-2001 GRAND MARQUIS, MOUNTAINEER ISSUE Some vehicles equipped with a 4R70W automatic transmission may exhibit a "clunk" noise during the 2-1 downshift event. The "clunk" noise will be consistent in nature, and will occur during most 2-1 downshifts. This may be caused by a Planet Support Spring that is out of position. ACTION Check for the correct installation of the Planet Support Spring. If the spring is not installed correctly, the Planetary Gear Support will make contact with the transmission case during the 2-1 downshift, causing the "clunk" noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THE "CLUNK" NOISE DESCRIBED IN THIS ARTICLE SHOULD NOT BE CONFUSED WITH HARSH/ROUGH 2-1 DOWNSHIFT CONDITION. IF A HARSH/ROUGH 2-1 SHIFT CONDITION IS PRESENT, FOLLOW NORMAL WORKSHOP MANUAL DIAGNOSTIC PROCEDURES. 1. Use Chassis Ears (Rotunda number 107-R2102 or equivalent) to verify the "clunk" noise is originating from the transmission during the 2-1 downshift event. NOTE IF THE NOISE IS NOT ORIGINATING FROM THE TRANSMISSION DO NOT CONTINUE WITH THIS SERVICE PROCEDURE. USE THE CHASSIS EARS TO HELP PINPOINT THE ORIGIN OF THE NOISE, THEN DIAGNOSE AND REPAIR AS NEEDED. 2. Raise and support vehicle. Refer to Workshop Manual Section 100-02. 3. Check for correct torque on the following chassis & drivetrain components: ^ Driveshaft to Pinion Flange fasteners ^ Upper and Lower Control Arm fasteners (car applications) ^ Rear Leaf Spring Fasteners (truck applications) ^ Rear Shock Absorber fasteners ^ Transmission Mount and Crossmember fasteners 4. If any discrepancies are found, correct and test drive vehicle to verify repair. If condition is not corrected, continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 5147 5. Remove the transmission from the vehicle and disassemble down to and including the Center Support Retaining Ring. Refer to Workshop Manual section 307-01. 6. Note the position of the Planet Support Spring. Compare to the correct installation which is illustrated in Figure 1. One tang of the Planet Support Spring should be loaded against the transmission case. The other tang should be loaded against the Planetary Gear Support. 7. Unless the Planet Support Spring is damaged, it may be reinstalled in the transmission correctly. If the spring is damaged, replace with part number F5AZ-7F277-AA. 8. Install the Planet Support Spring in the position illustrated in Figure 1. Use a flat/wide tool, that will apply equal force across the spring. This will ensure the spring is installed squarely with the tangs loading the Transmission Case on one side and the Planetary Gear Support on the other. 9. Reassemble and install the transmission. Replace the Pump Gasket during reassembly. Part number F2VY-7A136-A. 10. Lower vehicle, refill fluid to correct level and verity repair. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 5148 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 5149 Operation/Description/Time DEALER CODING CONDITION BASIC PART NO. CODE 7F277 07 OASIS CODES: 502000, 504000, 597997 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Planetary Gears: All Technical Service Bulletins A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Article No. 01-13-7 07/09/01 ^ NOISE - "CLUNK" NOISE HEARD ON 2-1 DOWNSHIFT VEHICLES EQUIPPED WITH 4R70W AUTOMATIC TRANSMISSION ^ TRANSMISSION - 4R70W - "CLUNK" NOISE HEARD FROM TRANSMISSION ON 2-1 DOWNSHIFT FORD: 1999-2001 CROWN VICTORIA, MUSTANG 1999 F-250 LD 1999-2001 E SERIES, EXPEDITION, EXPLORER, F-150 LINCOLN: 1999-2001 TOWN CAR MERCURY: 1999-2001 GRAND MARQUIS, MOUNTAINEER ISSUE Some vehicles equipped with a 4R70W automatic transmission may exhibit a "clunk" noise during the 2-1 downshift event. The "clunk" noise will be consistent in nature, and will occur during most 2-1 downshifts. This may be caused by a Planet Support Spring that is out of position. ACTION Check for the correct installation of the Planet Support Spring. If the spring is not installed correctly, the Planetary Gear Support will make contact with the transmission case during the 2-1 downshift, causing the "clunk" noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THE "CLUNK" NOISE DESCRIBED IN THIS ARTICLE SHOULD NOT BE CONFUSED WITH HARSH/ROUGH 2-1 DOWNSHIFT CONDITION. IF A HARSH/ROUGH 2-1 SHIFT CONDITION IS PRESENT, FOLLOW NORMAL WORKSHOP MANUAL DIAGNOSTIC PROCEDURES. 1. Use Chassis Ears (Rotunda number 107-R2102 or equivalent) to verify the "clunk" noise is originating from the transmission during the 2-1 downshift event. NOTE IF THE NOISE IS NOT ORIGINATING FROM THE TRANSMISSION DO NOT CONTINUE WITH THIS SERVICE PROCEDURE. USE THE CHASSIS EARS TO HELP PINPOINT THE ORIGIN OF THE NOISE, THEN DIAGNOSE AND REPAIR AS NEEDED. 2. Raise and support vehicle. Refer to Workshop Manual Section 100-02. 3. Check for correct torque on the following chassis & drivetrain components: ^ Driveshaft to Pinion Flange fasteners ^ Upper and Lower Control Arm fasteners (car applications) ^ Rear Leaf Spring Fasteners (truck applications) ^ Rear Shock Absorber fasteners ^ Transmission Mount and Crossmember fasteners 4. If any discrepancies are found, correct and test drive vehicle to verify repair. If condition is not corrected, continue to Step 5. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 5155 5. Remove the transmission from the vehicle and disassemble down to and including the Center Support Retaining Ring. Refer to Workshop Manual section 307-01. 6. Note the position of the Planet Support Spring. Compare to the correct installation which is illustrated in Figure 1. One tang of the Planet Support Spring should be loaded against the transmission case. The other tang should be loaded against the Planetary Gear Support. 7. Unless the Planet Support Spring is damaged, it may be reinstalled in the transmission correctly. If the spring is damaged, replace with part number F5AZ-7F277-AA. 8. Install the Planet Support Spring in the position illustrated in Figure 1. Use a flat/wide tool, that will apply equal force across the spring. This will ensure the spring is installed squarely with the tangs loading the Transmission Case on one side and the Planetary Gear Support on the other. 9. Reassemble and install the transmission. Replace the Pump Gasket during reassembly. Part number F2VY-7A136-A. 10. Lower vehicle, refill fluid to correct level and verity repair. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 5156 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 5157 Operation/Description/Time DEALER CODING CONDITION BASIC PART NO. CODE 7F277 07 OASIS CODES: 502000, 504000, 597997 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T Seals and Gaskets: Service and Repair Extension Housing Seal, A/T Special Tools Removal 1. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicles battery has been disconnected for any type of service or repair the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If this concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Note: 4x2 shown, 4x4 similar. Raise the vehicle on a hoist. 3. Remove the driveshaft. 4. With a suitable drain pan properly positioned, remove the (A) extension housing seal, using the (B) Seal Remover and the (C) Impact Slide Hammer. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5162 5. CAUTION: Do not damage any machined surfaces. Damage may cause the new seal to leak. Using the (A) Bushing Remover, remove the (B) extension housing bushing. Installation 1. CAUTION: Prior to installing the extension housing bushing, inspect the extension housing counterbore for burrs. If necessary, remove the burrs with an oil stone or damage to new bushing may occur. Note: The extension housing bushing is model dependent, refer to the parts catalog lair the correct part usage. Align the extension housing bushing in the extension housing so that the slots are in the 2 o'clock and 7 o'clock positions. 2. Using the (A) Extension Housing Bushing Replacer, install the (B) extension housing bushing. 3. Align the (A) extension housing seal in the extension housing, with the (B) drain hole positioned downward. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5163 4. Using the (A) Extension Housing Seal Replacer, seat the extension housing seal into the (B) extension housing. 5. Install the driveshaft. 6. Lower the vehicle. 7. Reconnect the battery ground cable. 8. Fill the transmission to the specified level with MERCON Multipurpose (ATF) Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5164 Seals and Gaskets: Service and Repair Shift Shaft Seal Special Tools Removal 1. Remove the fluid pan gasket and filter. 2. Disconnect the shift cable. 1 Disconnect the shift cable from the manual lever. 2 Disconnect the cable housing from the bracket; position aside. 3. Disconnect the digital Transmission Range (TR) sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5165 4. Remove the Digital Transmission (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. 5. Note: A No. 53 drill bit (1/16 inch) can be used instead to remove the manual lever shaft retaining pin. Remove the manual lever shaft retaining pin. 1 Install the special tool 211-S060 (T78P-3504-N) into the retaining pin. 2 Remove the manual lever shaft retaining pin. 6. CAUTION: Be careful not to damage the manual control lever bore. Note: The manual control lever and manual control lever shaft are one piece. Note: Use a crescent wrench on the manual control lever or outer flats of manual control lever shaft assembly when removing the inner manual valve detent lever nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5166 Remove the manual control lever shaft assembly. 1 Remove the nut. 2 Remove the manual control lever shaft assembly. 7. Remove the manual control lever seal. 1 Install the special tool 308-001 (T58L-101-B) 2 Remove the seal. Installation 1. Note: Prior to installing the manual control lever seal, clean the bore opening with mineral spirits. Using the special tool 307-050 (T74P-77498-A), install the manual control lever seal. 2. Install the manual control lever shaft assembly. 1 Install the manual control lever shaft assembly. 2 Install and seat the manual lever shaft retaining pin below the case surface. 3 Note: The inner manual valve detent lever must be seated on the flats of the manual control lever shaft assembly, and the parking pawl actuating rod must be through the guide plate. Note: The manual control valve detent lever spring must be on the inner manual valve detent lever, and the detent lever pin must align with the manual shift valve. Install the (A) parking pawl actuating rod and the (B) inner manual valve detent lever. 4 Note: Use a crescent wrench on the manual control lever or the outer flats of the manual control lever shaft assembly when installing the inner Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5167 manual valve detent lever nut. Install the timer manual valve detent lever nut. 3. Install the digital Transmission Range (TR) sensor. 1 Position the digital transmission range sensor. 2 Loosely install the bolts. 4. Note: Make sure that the manual control lever is in the neutral position. Install the Digital Transmission Range (TR) Sensor Alignment Tool. The tool is designed to fit snug. 5. Tighten the bolts. 6. Connect the digital Transmission Range (TR) sensor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Extension Housing Seal, A/T > Page 5168 7. Connect the shift cable. 1 Install the cable housing to the bracket. 2 Install the shift cable to the manual lever. 8. Install filter and seal assembly, fluid pan and gasket. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation Transmission Control Switch Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 5173 Transmission Mode Switch: Service and Repair Removal 1. Remove the Transmission Control (TC) switch. 1 Remove the TC switch cover. 2 Remove the TC switch. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission TR Sensor 71 - 88 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5177 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > 4R70W Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > 4R70W > Page 5180 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 5181 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 5182 Digital Transmission Range Sensor: Service and Repair Special Tools Removal 1. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If this concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 5183 5. Remove the digital Transmission Range (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. Installation 1. Install the digital Transmission Range (TR) sensor. 1 Install digital Transmission Range (TR) sensor. 2 Loosely install the bolts. 2. Note: Make sure that the manual control lever is in the neutral position. Install the TRS Alignment Gauge. The TRS Alignment Gauge is designed to fit snug. 3. Tighten the bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 5184 4. Reconnect the shift cable at the manual control lever. 5. Reconnect the connector. 6. Lower the vehicle. 7. Reconnect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 71 - 88 in.lb Turbine Shaft Speed (TSS) Sensor Bolt 71 - 88 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5188 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor > Page 5191 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5192 Transmission Speed Sensor: Service and Repair Removal 1. Remove the drive shaft. 2. Remove the rear transmission mount nuts. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Remove the rear transmission mount. 1 Raise the transmission up off the rear crossmember support. 2 Remove the bolts. 3 Remove the rear transmission mount. 4. Lower the transmission to gain access to the Turbine Shaft Speed (TSS) sensor, and the Output Shaft Speed (OSS) sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5193 5. Remove the Turbine Shaft Sensor (TSS). 1 Remove the bolt. 2 Remove the Turbine Shaft Sensor (TSS). 6. Remove the Output Shaft Speed (OSS) sensor. 1 Remove the bolt. 2 Remove the Output Shaft Speed (OSS) sensor. Installation 1. Install the Output Shaft Speed (OSS) sensor. 1 Lubricate the O-ring and install the Output Shaft Speed (OSS) sensor. 2 Install the bolt. 2. Install the Turbine Shaft Sensor (TSS). 1 Lubricate the O-ring and install the Turbine Shaft Sensor (TSS). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5194 2 Install the bolt. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the sensors will occur. Install the rear transmission mount. 1 Raise the transmission up. 2 Install the rear transmission mount. 3 Install the bolts. 4. Lower the transmission on to the rear crossmember support. 5. Install the rear transmission mount nuts. 6. Install the drive shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Lock <--> [Shift Interlock, A/T] > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications Shift Lock Actuator: Specifications Shift Lock Actuator Bolts 62.5 - 98 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Lock <--> [Shift Interlock, A/T] > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications > Page 5199 Shift Lock Actuator: Service and Repair Removal 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. 1 Remove the bolts. 2 Remove the insert plate and shift lock actuator. 3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair Shifter A/T: Service and Repair Removal 1. Remove the ignition switch lock cylinder. 2. Remove the upper steering column shroud. 3. Remove the gearshift lever. 1 Disconnect the electrical connector. 2 Remove and discard the gearshift lever pin. 3 Remove the gearshift lever. Installation 1. Note: The gearshift lever pin must be replaced whenever removed. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications Selector Shaft: Specifications Torque Specifications Parking Pawl Abutment ............................................................................................................................................................ 22-27 Nm (16-20 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 5207 Selector Shaft: Service and Repair Removal Note: For internal park mechanism service, refer to Manual Control Lever Shaft and Seal. 1. Remove the extension housing and the extension housing gasket. 2. Remove the parking rod guide plate. 1 Remove the bolts. 2 Remove the parking rod guide plate. 3. Note: If the park gear replacement is required; refer to Output Shaft-Check. Remove the park pawl shaft. 1 Remove the park pawl return spring. 2 Remove the park pawl. 3 Remove the park pawl shaft. Installation 1. Note: If the park gear replacement is required; refer to Output Shaft-Check. Install the park pawl shaft. 1 Install the park pawl shaft. 2 Install the park pawl. 3 Install the park pawl return spring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications > Page 5208 2. Install the parking rod guide plate. 1 Install the parking rod guide plate. 2 Install the bolts. 3. Install the extension housing gasket and the extension housing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications Shift Cable: Specifications Shift Cable Bracket Bolts 22-29 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 5212 Shift Cable: Adjustments 1. Place the gearshift lever in the (D) position. - Place an eight pound weight on the gearshift lever. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Disconnect the transmission shift cable from the manual control lever. 4. Unlock the lock tab on the transmission shift cable. 5. Place the manual control lever in the (D) position. 1 Place the manual control lever in the first gear position. 2 Move the manual control lever two detents to the (D) position. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 5213 6. Connect the transmission shift cable to the manual control lever. 7. Lock the transmission shift cable lock tab. 8. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 9. Remove the eight pound weight. 10. Carefully move the manual control lever from detent to detent and compare with transmission settings. Verify that the vehicle will start in PARK or NEUTRAL and backup lamps illuminate in REVERSE. If not, Steps 1-5 must be repeated and include digital Transmission Range (TR) or Transmission Range (TR) sensor adjustment in NEUTRAL. Readjust if necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 5214 Shift Cable: Service and Repair Removal 1. Disconnect the transmission shift cable from the steering column. 1 Disconnect the transmission shift cable from the transmission selector lever arm and support. 2 Disconnect the transmission shift cable from the steering column instrument panel bracket. 2. Disconnect the cable push pin. 3. Push the rubber grommet and transmission shift cable through the bulkhead. 4. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 5. Remove the transmission shift cable from the automatic transmission. 1 Disconnect the transmission shift cable from the manual control lever. 2 Depress the lock tabs to release the transmission shift cable and disconnect the transmission shift cable from the transmission shift cable bracket. 6. Remove the shift cable bracket from the transmission (4.6L). 1 Remove the bolts. 2 Remove the bracket. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > Page 5215 7. Remove the shift cable bracket from the transmission (5.4L). 1 Remove the bolts. 2 Remove the shift cable bracket. Installation 1. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Follow the removal procedure in reverse order. Adjust the shift cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges Torque Converter: Customer Interest A/T - Torque Converter Access Plug Dislodges Article No. 02-21-1 10/28/02 TRANSMISSION - 4R100/E4OD - TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED FORD: 1989-1996 BRONCO 1989-1997 F SUPER DUTY 1989-1998 F-250 LD, F-53 MOTORHOME 1989-2003 E SERIES, F-150 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2003 EXCURSION LINCOLN: 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD ISSUE Some vehicles equipped with the E4OD/4R100 transmission may exhibit the torque converter external access dust plug dislodging and falling out during severe duty use. This may be caused by a combination of stack up tolerance, material shrinkage over time and loading being applied to the plug during usage or cleaning of the underside of the vehicle. ACTION Obtain new plug (E9TZ-7N171-A) and apply 1/4" bead of silicone sealant around entire perimeter of part and install plug into transmission case. The silicone is to be applied in the groove of the part such that when it is installed, the sealant will till any gaps between the transmission case and the plug. SERVICE PROCEDURE 1. Obtain service part E9TZ-7N171-A, F7TZ-19554-AA and general purpose degreaser such as Motorcraft Brake Parts Cleaner, PM-4. 2. Clean transmission case casting in the area of the plug using general purpose degreaser making sure the area is free from grease and other contaminants. 3. Apply a 1/4" bead of silicone sealant F7TZ-19554-AA to plug E9TZ-7N171-A making sure that the groove in the plug is filled with silicone sealant. 4. Immediately install plug into the transmission case casting smoothing out any overflow that may occur during installation. PART NUMBER PART NAME PM-4 Motorcraft Brake Parts Cleaner E9TZ-7N171-A Plug - Converter Access F7TZ-19554-AA Ultra Silicone Sealant OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022101A Install Torque Converter 0.2 Hr. Access External Dust Plug - 1989-1996 Bronco, 1989-1997 F-150, F250LD, F-Super Duty, E-Series, Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges > Page 5224 1998-2003 F-150, Lightning, Harley Davidson, F-250LD, Super Duty F-Series, E-Series, 2000-2003 Excursion, 1989-2003 Motor Home Stripped Chassis, 1997-2003 Expedition, Navigator, 2002-2003 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 7N171 39 OASIS CODES: 504000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges Torque Converter: All Technical Service Bulletins A/T - Torque Converter Access Plug Dislodges Article No. 02-21-1 10/28/02 TRANSMISSION - 4R100/E4OD - TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED FORD: 1989-1996 BRONCO 1989-1997 F SUPER DUTY 1989-1998 F-250 LD, F-53 MOTORHOME 1989-2003 E SERIES, F-150 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2003 EXCURSION LINCOLN: 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD ISSUE Some vehicles equipped with the E4OD/4R100 transmission may exhibit the torque converter external access dust plug dislodging and falling out during severe duty use. This may be caused by a combination of stack up tolerance, material shrinkage over time and loading being applied to the plug during usage or cleaning of the underside of the vehicle. ACTION Obtain new plug (E9TZ-7N171-A) and apply 1/4" bead of silicone sealant around entire perimeter of part and install plug into transmission case. The silicone is to be applied in the groove of the part such that when it is installed, the sealant will till any gaps between the transmission case and the plug. SERVICE PROCEDURE 1. Obtain service part E9TZ-7N171-A, F7TZ-19554-AA and general purpose degreaser such as Motorcraft Brake Parts Cleaner, PM-4. 2. Clean transmission case casting in the area of the plug using general purpose degreaser making sure the area is free from grease and other contaminants. 3. Apply a 1/4" bead of silicone sealant F7TZ-19554-AA to plug E9TZ-7N171-A making sure that the groove in the plug is filled with silicone sealant. 4. Immediately install plug into the transmission case casting smoothing out any overflow that may occur during installation. PART NUMBER PART NAME PM-4 Motorcraft Brake Parts Cleaner E9TZ-7N171-A Plug - Converter Access F7TZ-19554-AA Ultra Silicone Sealant OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022101A Install Torque Converter 0.2 Hr. Access External Dust Plug - 1989-1996 Bronco, 1989-1997 F-150, F250LD, F-Super Duty, E-Series, Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges > Page 5230 1998-2003 F-150, Lightning, Harley Davidson, F-250LD, Super Duty F-Series, E-Series, 2000-2003 Excursion, 1989-2003 Motor Home Stripped Chassis, 1997-2003 Expedition, Navigator, 2002-2003 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 7N171 39 OASIS CODES: 504000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 5231 Torque Converter: Specifications Torque Converter-To-Flexplate Nut 22 - 30 ft.lb Torque Converter Drain Plug 18 - 23 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Transmission Cooler: Customer Interest A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 5240 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 5241 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 5242 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips Transmission Cooler: All Technical Service Bulletins A/T - Cooler Flushing Service Tips Article No. 03-14-8 07/21/03 TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS FORD: 1992-1997 CROWN VICTORIA, PROBE, THUNDERBIRD 1992-2003 ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1992-1996 BRONCO 1992-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1992-1999 F-250 LD 1992-2003 ECONOLINE, EXPLORER, F-150, RANGER 1995-2003 WINDSTAR 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1992-1997 TOWN CAR 1992-2002 CONTINENTAL 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD 2003 AVIATOR MERCURY: 1992-1997 COUGAR, GRAND MARQUIS 1992-2000 TRACER 1992-2003 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER This article supersedes TSB 00-1-5. ISSUE The number one cause for repeat transmission repairs is that contamination from the transmission cooler system (lines and tank) will work their way back into the rebuilt or new transmission. For this reason a new transmission cooler flusher has been released, "Turbo-Tank Heated Cooler Line Flusher" Rotunda Tool number 22-00001. ACTION The transmission cooling system (cooler and lines) MUST be flushed every time the transmission is overhauled or replaced in order to minimize the likelihood of repeat repairs. The use of this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001) is the most effective way to remove contamination from its cooling system. Refer to the following Service Procedure and Equipment instructions (supplied with the "Turbo-Tank Heated Cooler Line Flusher"). SERVICE PROCEDURE Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant removal that is required to prevent repeat repairs. The "Turbo-Tank Heated Cooler Line Flusher" uses heated Automatic Transmission Fluid (ATF) and a pulsating action to loosen system contamination. Previous equipment used solvents to clean & flush coolers, lines and torque-converters. There are 2 issues with this method: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 5248 ^ Residual solvent contamination can cause damage to friction bonding materials within the transmission (Clutches and Bands). ^ Lack of fluid heating and agitation prevents this method from completely removing contamination from lines, in-radiator coolers and auxiliary coolers. Aerosol Solvents should never be used for several reasons. ^ They do not provide the volume necessary to remove heavy contaminants. ^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they are as the solvent dries. NOTE YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING PROCEDURE. A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the transmission) is to locate the return cooler line fitting on the transmission case. Refer to the following lists: Rear Wheel Drive ^ TORQSHIFT, 4R100, E40D, C6 - The REAR transmission case filling receives the return line. ^ 4R70W, AODE, AOD - The TOP transmission case filling receives the return line. ^ A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S - The TOP transmission case filling receives the return line. Front Wheel Drive ^ CD4E - The REAR or Pump End transaxle case fitting receives the return line. ^ 4F27E - The REAR or Cover End transaxle case fitting receives the return line. ^ AXOD, AXODE, AX4S, AX4N, 4F50N - The BOTTOM transaxle cooler line fitting receives the return line. NOTE IF AN IN-LINE FILTER HAS BEEN INSTALLED IN THE COOLER LINE, IT MUST BE REMOVED BEFORE FLUSHING THE COOLER OR COOLER LINES. Purge the cooler and cooler line before flushing: Located on the "Turbo-Tank Heated Cooler Line Flusher" is a fluid transfer and purge valve. This valve can be used to purge the cooler and cooler lines of contaminated fluid before starting the back flush procedure of the fluid cooling system (refer to step 5a of this Service Procedure or Equipment instructions, supplied with the "Turbo-Tank Heated Cooler Line Flusher"). Flush Procedure 1. Check and top off fluid level of the "Turbo-Tank Heated Cooler Line Flusher" tank with transmission fluid. 2. Allow the fluid in the flusher 15-30 minutes to heat up to 140° F (60° C) before using. 3. Install line adapters into the transmission cooler lines. 4. Attach the flusher's blue line to the transmission return cooler line quick disconnect. 5. Attach the flusher's red line to the transmission outlet cooler line quick disconnect. a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing procedure (using factory installed purge valve and clear hose on "Turbo-Tank Heated Cooler Line Flusher"). 6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a forward/normal flow direction for an additional 10-15 minutes. For ordering information on this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001), contact Rotunda at 800-ROTUNDA (800-768-8632 or outside U.S. 262-656-5805). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 5249 CAUTION THIS FLUSHER CANNOT BE USED TO FLUSH COOLERS ON VEHICLES EQUIPPED WITH THE TEMPERATURE BYPASS-TYPE TRANSMISSION COOLER CURRENTLY FOUND IN 1998-2003 CROWN VICTORIA, GRAND MARQUIS, AND TOWN CAR VEHICLES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-1-5 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Transmission Cooler: All Technical Service Bulletins A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 5254 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 5255 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 5256 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips Transmission Cooler: All Technical Service Bulletins A/T - Cooler Flushing Service Tips Article No. 03-14-8 07/21/03 TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS FORD: 1992-1997 CROWN VICTORIA, PROBE, THUNDERBIRD 1992-2003 ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1992-1996 BRONCO 1992-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1992-1999 F-250 LD 1992-2003 ECONOLINE, EXPLORER, F-150, RANGER 1995-2003 WINDSTAR 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1992-1997 TOWN CAR 1992-2002 CONTINENTAL 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD 2003 AVIATOR MERCURY: 1992-1997 COUGAR, GRAND MARQUIS 1992-2000 TRACER 1992-2003 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER This article supersedes TSB 00-1-5. ISSUE The number one cause for repeat transmission repairs is that contamination from the transmission cooler system (lines and tank) will work their way back into the rebuilt or new transmission. For this reason a new transmission cooler flusher has been released, "Turbo-Tank Heated Cooler Line Flusher" Rotunda Tool number 22-00001. ACTION The transmission cooling system (cooler and lines) MUST be flushed every time the transmission is overhauled or replaced in order to minimize the likelihood of repeat repairs. The use of this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001) is the most effective way to remove contamination from its cooling system. Refer to the following Service Procedure and Equipment instructions (supplied with the "Turbo-Tank Heated Cooler Line Flusher"). SERVICE PROCEDURE Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant removal that is required to prevent repeat repairs. The "Turbo-Tank Heated Cooler Line Flusher" uses heated Automatic Transmission Fluid (ATF) and a pulsating action to loosen system contamination. Previous equipment used solvents to clean & flush coolers, lines and torque-converters. There are 2 issues with this method: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 5262 ^ Residual solvent contamination can cause damage to friction bonding materials within the transmission (Clutches and Bands). ^ Lack of fluid heating and agitation prevents this method from completely removing contamination from lines, in-radiator coolers and auxiliary coolers. Aerosol Solvents should never be used for several reasons. ^ They do not provide the volume necessary to remove heavy contaminants. ^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they are as the solvent dries. NOTE YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING PROCEDURE. A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the transmission) is to locate the return cooler line fitting on the transmission case. Refer to the following lists: Rear Wheel Drive ^ TORQSHIFT, 4R100, E40D, C6 - The REAR transmission case filling receives the return line. ^ 4R70W, AODE, AOD - The TOP transmission case filling receives the return line. ^ A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S - The TOP transmission case filling receives the return line. Front Wheel Drive ^ CD4E - The REAR or Pump End transaxle case fitting receives the return line. ^ 4F27E - The REAR or Cover End transaxle case fitting receives the return line. ^ AXOD, AXODE, AX4S, AX4N, 4F50N - The BOTTOM transaxle cooler line fitting receives the return line. NOTE IF AN IN-LINE FILTER HAS BEEN INSTALLED IN THE COOLER LINE, IT MUST BE REMOVED BEFORE FLUSHING THE COOLER OR COOLER LINES. Purge the cooler and cooler line before flushing: Located on the "Turbo-Tank Heated Cooler Line Flusher" is a fluid transfer and purge valve. This valve can be used to purge the cooler and cooler lines of contaminated fluid before starting the back flush procedure of the fluid cooling system (refer to step 5a of this Service Procedure or Equipment instructions, supplied with the "Turbo-Tank Heated Cooler Line Flusher"). Flush Procedure 1. Check and top off fluid level of the "Turbo-Tank Heated Cooler Line Flusher" tank with transmission fluid. 2. Allow the fluid in the flusher 15-30 minutes to heat up to 140° F (60° C) before using. 3. Install line adapters into the transmission cooler lines. 4. Attach the flusher's blue line to the transmission return cooler line quick disconnect. 5. Attach the flusher's red line to the transmission outlet cooler line quick disconnect. a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing procedure (using factory installed purge valve and clear hose on "Turbo-Tank Heated Cooler Line Flusher"). 6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a forward/normal flow direction for an additional 10-15 minutes. For ordering information on this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001), contact Rotunda at 800-ROTUNDA (800-768-8632 or outside U.S. 262-656-5805). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 5263 CAUTION THIS FLUSHER CANNOT BE USED TO FLUSH COOLERS ON VEHICLES EQUIPPED WITH THE TEMPERATURE BYPASS-TYPE TRANSMISSION COOLER CURRENTLY FOUND IN 1998-2003 CROWN VICTORIA, GRAND MARQUIS, AND TOWN CAR VEHICLES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-1-5 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 5264 Transmission Cooler: Specifications Transmission fluid cooler fittings 15 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Backflushing and Cleaning Transmission Cooler: Service and Repair Backflushing and Cleaning TRANSMISSION FLUID COOLER-BACKFLUSHING AND CLEANING 1. Using a suitable torque converter/fluid cooler cleaner, flush the fluid cooler and lines. 2. Note: Rubber hoses must be attached to the ends of the fluid cooler tubes, to aid in connecting them to the cleaner. Connect the cleaner pressure and return lines appropriately. 1 Connect the pressure line to fluid cooler inlet tube. 2 Connect the return line to fluid cooler outlet tube. 3 Place the outlet end of the return line in the solvent tank reservoir. 3. Note: Cycling the solvent pump on and off will help dislodge contaminants in the cooler system. Switch the solvent pumps on. Allow the solvent to circulate a minimum of 5 minutes. 4. Switch the solvent pump off. 5. Disconnect the cleaner pressure line at the fluid cooler tube. 6. Using compressed air, blow through the fluid cooler inlet tube until all solvent is removed. 7. Remove the rubber hoses from fluid cooler tubes. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Backflushing and Cleaning > Page 5267 Transmission Cooler: Service and Repair Removal and Installation Removal 1. Remove the front skid plate. 1 Remove the bolts. 2 Remove the front skid plate. 2. Place a drain pan under the auxiliary transmission fluid cooler. 3. Remove the auxiliary transmission fluid cooler 1 Disconnect the auxiliary transmission fluid cooler tubes. 2 Remove the bolts. 3 Remove the auxiliary transmission fluid cooler Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Backflushing and Cleaning > Page 5268 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation Transmission Control Switch Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation > Page 5272 Transmission Mode Switch: Service and Repair Removal 1. Remove the Transmission Control (TC) switch. 1 Remove the TC switch cover. 2 Remove the TC switch. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications Transmission Mount: Specifications Transmission Insulator And Retainer To Case Bolts 60 - 80 ft.lb Transmission Insulator And Retainer To Crossmember Nuts 60 - 80 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Page 5276 Transmission Mount: Service and Repair Special Tools Removal 1. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If this concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Remove the nuts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Page 5277 4. Secure the (A) High Lift Transmission Jack with the (B) E40D Transmission Jack Adapter to the (C) transmission. 5. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Raise the transmission jack until the (A) retainer studs are separated from the (B) transmission support crossmember. 6. Remove the (A) bolts and the (B) retainer. Installation 1. Install the (A) retainer and the (B) bolts. 2. Lower the transmission jack while aligning the (A) retainer studs with the holes in the (B) transmission support crossmember. Allow the full weight of the transmission to rest on the transmission support crossmember Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > Page 5278 3. Install the nuts. 4. Remove the (A) High Lift Transmission Jack with the (B) E40D Transmission Jack Adapter from the (C) transmission. 5. Reinstall the transmission fluid pan-to-case retaining bolts removed to install the jack adapter. 6. Lower the vehicle. 7. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission TR Sensor 71 - 88 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5282 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > 4R70W Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > 4R70W > Page 5285 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 5286 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 5287 Digital Transmission Range Sensor: Service and Repair Special Tools Removal 1. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If this concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 5288 5. Remove the digital Transmission Range (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. Installation 1. Install the digital Transmission Range (TR) sensor. 1 Install digital Transmission Range (TR) sensor. 2 Loosely install the bolts. 2. Note: Make sure that the manual control lever is in the neutral position. Install the TRS Alignment Gauge. The TRS Alignment Gauge is designed to fit snug. 3. Tighten the bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 5289 4. Reconnect the shift cable at the manual control lever. 5. Reconnect the connector. 6. Lower the vehicle. 7. Reconnect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 71 - 88 in.lb Turbine Shaft Speed (TSS) Sensor Bolt 71 - 88 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5293 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor > Page 5296 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5297 Transmission Speed Sensor: Service and Repair Removal 1. Remove the drive shaft. 2. Remove the rear transmission mount nuts. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Remove the rear transmission mount. 1 Raise the transmission up off the rear crossmember support. 2 Remove the bolts. 3 Remove the rear transmission mount. 4. Lower the transmission to gain access to the Turbine Shaft Speed (TSS) sensor, and the Output Shaft Speed (OSS) sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5298 5. Remove the Turbine Shaft Sensor (TSS). 1 Remove the bolt. 2 Remove the Turbine Shaft Sensor (TSS). 6. Remove the Output Shaft Speed (OSS) sensor. 1 Remove the bolt. 2 Remove the Output Shaft Speed (OSS) sensor. Installation 1. Install the Output Shaft Speed (OSS) sensor. 1 Lubricate the O-ring and install the Output Shaft Speed (OSS) sensor. 2 Install the bolt. 2. Install the Turbine Shaft Sensor (TSS). 1 Lubricate the O-ring and install the Turbine Shaft Sensor (TSS). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5299 2 Install the bolt. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the sensors will occur. Install the rear transmission mount. 1 Raise the transmission up. 2 Install the rear transmission mount. 3 Install the bolts. 4. Lower the transmission on to the rear crossmember support. 5. Install the rear transmission mount nuts. 6. Install the drive shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair Valve Body: Service and Repair Removal Note: If the transmission has been disassembled to replace worn or damaged parts, and the valves in the main control valve body stick repeatedly from foreign material, the torque converter must be removed and cleaned by using a mechanically agitated cleaner, such as the Torque Converter/Oil Cooler Cleaner. 1. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If this concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the solenoid body electrical connector. 4. Remove the fluid pan gasket and filter. 5. Remove the accumulator body. 1 Remove the bolts. 2 Remove the nuts. 3 Remove the accumulator body. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Page 5303 6. CAUTION: Prevent the front of the valve body separator plate from sagging and displacing the check balls. If the valve body separator plate is not being serviced: 1 Remove the bolt. 2 Install the bolt into any case-threaded bolt hole on the opposite end of the separator plate. 7. Remove the main control valve body assembly. 1 Remove the bolts. 2 Remove the nuts. 3 Remove the main control valve body. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Page 5304 8. Remove the solenoid body assembly. 1 Remove the bolts. 2 Remove the nut. 3 Remove the solenoid body assembly. 9. Remove the solenoid screen assembly by rotating and pulling. 10. CAUTION: The steel Electronic Pressure Control (EPC) check ball is spring-loaded under the valve body separator plate. Note: If the valve body separator plates are not to be serviced, proceed to installation procedure. Remove the valve body separator plate reinforcement. 1 Remove the bolts. 2 Remove the separator plate reinforcement. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Page 5305 11. Lower and remove the valve body separator plate and gaskets. - The rubber check balls and the steel EPC check ball and spring assembly will fall out and may become lost or stick to the worm trail of the case. - Remove and discard separator plate gaskets. Installation CAUTION: Using the incorrect gaskets can cause damage to the transmission. 1. Note: Refer to parts catalog for proper gasket usage. Note: If the valve body separator plate was not removed, proceed to Step 6. Note: Apply a light film of petroleum jelly to the valve body separator plate prior to assembling the new gaskets. Assemble the new gaskets to the valve body separator plate. 1 Main control to case gasket. 2 Valve body separator plate. 3 Main control to separator plate gasket. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Page 5306 2. Note: Apply a small amount of petroleum jelly to each check ball prior to positioning them on the valve body separator plate. Install eight rubber and one steel EPC check balls. 3. Note: Apply petroleum jelly to the EPC check ball spring prior to installing it into the case. Install the EPC check ball spring. 4. Position the valve body separator plate and the gaskets to the case carefully to retain the check balls. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Page 5307 5. Note: The word "UP" stamped on the separator plate reinforcement, must be visible when installed. Install the separator plate reinforcement plate. 1 Position the separator plate reinforcement plate. 2 Install the bolts. 6. Install the solenoid screen assembly by pushing it in and rotating it to lock. 7. Note: Prior to installing the solenoid body assembly, coat the case connector bore with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A. Install the solenoid body assembly. 1 Install the solenoid body assembly. 2 Install the nut. 3 Install the bolts and nut finger-tight. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Page 5308 8. Install the main control valve body. 1 Install the main control valve body. 2 Aligning the manual shift valve with the manual valve detent lever. 3 Install the nuts finger-tight. 4 Install the bolts finger-tight. 9. If previously installed, remove, then reinstall the bolt into the separator plate reinforcing plate. 1 Remove the bolt. 2 Install the bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Page 5309 10. Install the accumulator body. 1 Install the accumulator body. 2 Install the nuts finger-tight. 3 Install the bolts finger-tight. 11. Tighten all the accumulator body, main control valve body, and solenoid body nuts and bolts. Tighten the bolts working from the center to the outside. 12. Install the fluid pan gasket and filter. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Page 5310 13. Connect the solenoid body electrical connector. 14. Lower the vehicle. 15. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation The Clutch Pedal Position (CPP) switch is controlled by the clutch pedal. Depressing the clutch pedal manually closes the CPP switch and allows engine cranking. The CPP switch will also deactivate the speed control system. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Component Information > Service and Repair Differential Carrier: Service and Repair Differential Carrier Removal 1. Remove the axle shafts. 2. CAUTION: Index-mark the position of the differential bearing caps, as arrows may not be visible. The differential bearing caps must be installed in their original locations and positions. Remove the differential bearing cap bolts and the differential bearing caps. 3. WARNING: Be careful not to allow the differential assembly to fall. CAUTION: Place a wood block between the pry bar and the axle housing to protect the machined surface from damage. CAUTION: Index-mark the position ofthe differential bearing shims. The differential bearing shims must be installed in their original locations and positions. Using pry bars and wood blocks remove the differential assembly from the axle housing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Component Information > Service and Repair > Page 5319 Installation 1. Position the differential assembly in the axle housing. 2. Install the removed differential bearing shim on the LH side. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Component Information > Service and Repair > Page 5320 3. NOTE: Apply pressure towurd the LH side to muke sure the LH differential bearing cap is seated. Install the LH differential bearing cap and loosely install the differential bearing cap bolts. 4. Install the original differential bearing shim on the RH side. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Component Information > Service and Repair > Page 5321 5. Using the special tool fully seat the differential bearing shims. 6. Install the RH side differential bearing cap and tighten the LH side and RH side differential bearing cap bolts. ^ Tighten to 105 Nm (77 lb ft). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Component Information > Service and Repair > Page 5322 7. Rotate the differential assembly to make sure it rotates freely. 8. Measure the ring and pinion backlash. 9. Install the axle shafts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Front Differential Case: Specifications Front Differential case maximum runout .............................................................................................................................................. 0.076 mm ((0.003 inch) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Specifications > Front > Page 5327 Differential Case: Specifications Rear Ford - 8.8 Inch Ring Gear Differential case maximum runout .................................................................................................................................................... 0.076 mm (0.003 inch) Ford - 9.75 Inch Ring Gear Differential case maximum runout ................................................................................................................................................ 0.076 mm (0.003 inch) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front Differential Case: Service and Repair Front Disassembly 1. Remove the differential assembly from the differential carrier housing. 2. Remove the ring gear. - Remove the ten bolts. - Use a drift punch to separate the ring gear from the differential case. 3. Remove the differential pinion shaft bolt. 4. Remove the differential pinion shaft. 5. Remove the differential pinion thrust washers and the differential pinion gears. 1 Rotate the differential pinion gears to the differential case window, and remove them. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5330 2 Separate the thrust washers from the gears. 6. Remove the differential side gears and the differential side gear thrust washers. Assembly 1. Lubricate the differential side gear thrust washers and the differential side gear journals with Motorcraft SAE 75W-90 Premium 4x4 Front Axle Lubricant XY-75W90-TQL or equivalent meeting Ford specification WSP-M2C201-A. 2. Position the differential side gear thrust washers on the differential side gears. 3. Position the differential side gears. 4. Lubricate the differential pinion thrust washers and the differential pinion gears and assemble them. - Use Motorcraft SAE 75W-90 Premium 4x4 Front Axle Lubricant XY-75W90-TQL or equivalent meeting Ford specification WSP-M2C201-A. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5331 5. Engage the differential pinion gears opposite the differential side gears. 6. Rotate the differential pinion gears to align with the differential pinion shaft bore. 7. Insert the differential pinion shaft. 8. Note: If a new pinion shaft bolt is unavailable, coat the threads with Threadlock and Sealer E0AZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation. Install a new differential pinion shaft bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5332 9. CAUTION: Do not press on the bearing. Install the ring gear. 1 Position three bolts to align the holes in the ring gear and the differential case. 2 Using a suitable press, install the ring gear. 10. Install the remaining bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5333 Differential Case: Service and Repair Rear Removal and Installation Special Tools Removal 1. Remove the bolts on both sides, and position the rear stabilizer bar aside. 2. Remove the bolt, and position the rear axle tracking bar aside. 3. Remove the axle shafts. 4. Wipe the lubricant from the internal working parts and inspect the parts for wear and damage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5334 5. Rotate the differential assembly to check for roughness indicating bearing/gear damage. 6. Note: There is a space between the anti-lock speed sensor ring and the differential ring gear for measuring the differential ring gear backface runout. Using a suitable dial indicator and the special tool, measure and note the differential ring gear backface runout. 7. CAUTION: Mark the position and location of the bearing caps, as the arrows may not be visible. Always install the bearing caps in their identical locations and positions. Remove the bearing caps. 1 Remove the bolts. 2 Remove the bearing caps. 8. WARNING: Do not allow the differential assembly to fall. CAUTION: Place a wood block between the pry bar and the differential housing to protect the machined surface from damage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5335 Using a pry bar and a wood block, remove the differential assembly from the differential housing. 9. Remove the bolts. 10. CAUTION: Do not damage the differential ring gear bolt hole threads. CAUTION: If removing the anti-lock speed sensor ring, discard it, and install a new anti-lock speed sensor ring during installation. Insert a punch in the bolt holes, and drive off the differential ring gear and, if necessary, the anti-lock speed sensor ring. 11. If the differential ring gear backface runout measurement, taken at the beginning of this procedure, did not exceed the specification, proceed to the appropriate procedure as necessary: Drive Pinion, Differential Case and Ring Gear-Conventional or Differential Case and Ring Gear-Traction-Lok, or to Installation. If the differential ring gear backface runout measurement, taken at the beginning of this procedure, exceeded the specification, the cause may be a warped differential ring gear, differential case/differential bearing damage. Proceed as follows to verify the cause of the excessive runout. 12. Position the differential assembly, including the differential bearing cups and differential bearing shims, in the differential housing. Install the bearing caps and the bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5336 13. Position the special tool. 1 Rotate the differential case to verify that the differential bearings have seated correctly. 2 Position the special tool. 14. Measure and note the differential case runout. - If the runout does not exceed the specification, install a new differential ring gear and pinion. - If the runout exceeds the specification, the differential ring gear is true and the concern is due to either differential case/differential bearing damage. Proceed as follows. 15. Using the special tools, remove the differential bearings. 16. Using the special tool, install the new differential bearings. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5337 17. Position the differential assembly, including the differential bearing cups and differential bearing shims in the differential housing. Tighten bearing caps to specification. 18. Position the special tool. 1 Rotate the differential case to verify that the differential bearings have seated correctly. 2 Position the special tool. 19. Measure the differential case runout. - If the runout does not exceed the specification, use the new differential bearings for assembly. - If the runout exceeds the specification, install a new differential case. Installation All vehicles 1. CAUTION: If installing a new anti-lock speed sensor ring, align the notch on the case flange and the tab on the anti-lock speed sensor ring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5338 Position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the differential case. 2. Install the bolts. - Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2C349-A1 to the bolt threads. 3. With the pinion depth set and pinion installed, place the differential assembly in the differential housing. 4. Install a differential bearing shim on the left side. 5. CAUTION: Always install the bearing caps in their identical locations and positions. Note: Apply pressure toward the left side to make sure the left differential bearing cup seats correctly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5339 Install the left bearing cap and loosely install the bolts. 6. Install progressively larger differential bearing shims on the right side until the largest shim selected is installed by hand. 7. Install the right side bearing cap and tighten the left side and right side bolts to specification. 8. Rotate the differential case to make sure it turns freely. Measuring backlash Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5340 9. Using the special tools, measure and note the differential ring gear backlash. - If backlash is within the specification, refer to Backlash within specification. The specification shown is the full allowable range. - If a zero backlash condition occurs, refer to Zero backlash. - If backlash is not within the specification, refer to Backlash not within specification. Zero backlash 10. If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51 mm (0.020 inch) from the LH side to allow backlash indication. Measure the backlash. Backlash not within specification Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5341 11. To increase or decrease backlash, remove the bearing caps and install a thicker shim and a thinner shim accordingly. - If backlash is not within the specification, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. 12. Rotate the differential assembly several times to verify that the differential bearings seated correctly. 13. Using the special tools, recheck the backlash. - If backlash is within the specification, refer to Backlash within specification in this procedure. If backlash is not within the specification, repeat Backlash not within specification. - The specification shown is the full allowable range. Backlash within specification 14. Remove the bolts and the bearing caps. 15. To establish differential bearing preload, increase both left and right differential bearing shim sizes by the specification shown. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5342 16. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely. 17. Install the bearing caps and bolts. 18. Using the special tools, recheck the backlash. - The specification shown is the full allowable range. 19. Install the axle shafts. 20. Position the rear axle tracking bar in the bracket. Install the bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5343 21. Position the rear stabilizer bar. Install the bolts on both sides. Conventional Differential Case and Ring Gear Special Tools Disassembly 1. Remove the differential assembly from the differential housing. 2. Remove the bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5344 3. CAUTION: Do not damage the differential ring gear bolt hole threads. CAUTION: If removing the anti-lock speed sensor ring, discard it, and install a new anti-lock speed sensor ring during assembly. Insert a punch in the bolt holes, and drive off the differential ring gear and, if necessary, the anti-lock speed sensor ring. 4. Using the special tools, remove the differential bearings, if necessary. 5. Remove the bolt. 6. Remove the differential pinion shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5345 7. Rotate and remove the differential pinion gears and differential pinion thrust washers. 8. Remove the differential side gears and differential side gear thrust washers. Assembly 1. Lubricate the differential side gear thrust washers and the differential side gear journals. - Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Position the differential side gear thrust washers on the differential side gears. 3. Position the differential side gear and thrust washer assemblies in the differential case. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5346 4. Lubricate and assemble the differential pinion thrust washers and differential pinion gears. - Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 5. Engage the differential pinion gears opposite the differential side gears. 6. Rotate the differential pinion gears to align with the differential pinion shaft bore. 7. Insert the differential pinion shaft. - Align the bolt hole in the differential pinion shaft with the bolt hole in the differential case. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5347 8. Note: If a new bolt is unavailable, coat the threads with Threadlock and Sealer E0AZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation. Install a new bolt finger-tight. 9. Using the special tool, install the new differential bearings. 10. CAUTION: If installing a new anti-rock speed sensor ring, align the notch on the case flange and the tab on the anti-lock speed sensor ring. Position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the differential case. 11. Install the bolts. - Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the bolt threads. 12. Install the differential assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5348 Traction-LOK Differential Case and Ring Gear Special Tools Disassembly 1. Remove the differential assembly from the differential housing. 2. Remove the bolts. 3. CAUTION: Do not damage the bolt hole threads. CAUTION: If removing the anti-lock speed sensor ring, discard it, and install a new anti-lock speed sensor ring during assembly. Insert a punch in the bolt holes, and drive off the differential ring gear and, if necessary, the anti-lock speed sensor ring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5349 4. Using the special tools, remove the differential bearings. 5. Remove the bolt and remove the differential pinion shaft. 6. WARNING: Due to the spring tension, use care when removing the differential clutch spring. Failure to follow these instructions may result in personal injury. Remove the differential clutch spring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5350 7. Remove the differential gears. 1 Remove the two differential pinion gears. 2 Remove the two differential side gears. 3 Remove the two differential pinion thrust washers. 8. CAUTION: Keep the differential clutch packs in order. Do not mix them. Always reassemble them in the same sequence. Separate the differential clutch packs and shims from the differential side gears and tag them "right" and "left." Clean and inspect the remaining differential components for wear and damage and install new parts as necessary. 9. CAUTION: Do not use acids or solvents when cleaning the differential clutch packs. Wipe the components only with a clean, lint-free cloth. Clean and inspect the differential clutch packs for wear and damage and install new parts as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5351 Assembly 1. CAUTION: 118 ml (4 oz) of the Additive Friction Modifier must be used in the axle. Lubricate each steel clutch plate and soak all the friction plates for no less than 15 minutes. Use Additive Friction Modifier C8AZ-13B546-A or equivalent meeting Ford specification EST-M2C118-A 2. CAUTION: Do not mix the clutch plates, clutch discs or shim from one side with the other. Assemble the differential clutch packs (without the shims) on their respective differential side gear. 3. CAUTION: Use the correct mandrel with the special tool. Place the base portion of the special tool in a vise. Install the differential side gear and differential clutch pack (without the shim) on the tool. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5352 4. Position the special tool hand-tight on top of the differential clutch pack. 5. Install the special tool over the disc and differential clutch pack. 6. Install the nut. 7. Select and insert the thickest feeler gauge blade that will enter between the tool and the differential clutch pack. The reading will be the thickness Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5353 of the new clutch shim. 8. Remove the special tools from the differential clutch pack and differential side gear assembly. 9. Install the shim(s) on the differential clutch pack and differential side gear assembly. 10. Install the differential side gear assemblies in the differential case. 11. Install the differential pinion gear and differential pinion thrust washer assemblies in the differential case. 12. Using a soft-faced hammer, install the differential clutch spring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5354 13. Note: If a new bolt is unavailable, coat the threads with Threadlock and Sealer E0AZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation. Install the differential pinion shaft and install a new bolt finger-tight. 14. Mount the differential case and the special tool in a vise. Using the special tool, check the torque necessary to rotate one differential side gear. - If reusing the original clutch plates, the initial minimum break-away torque must be no less than the specification. The minimum rotating torque necessary to keep the differential side gear turning with new clutch plates may vary. 15. Using the special tool, install the differential bearings. 16. CAUTION: If installing a new anti-lock speed sensor ring, align the notch on the case Range and the tab on the anti-lock speed sensor ring. Position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the differential case. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5355 17. Install the bolts. - Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to bolt threads. 18. Install the differential assembly. Removal and Installation Special Tools Removal 1. Remove the differential housing cover and drain the axle. 2. Remove the axle shafts. 3. Wipe the lubricant from the internal working parts, and visually inspect the parts for wear or damage. 4. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5356 5. Note: There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear backface runout. Position the special tool, and inspect ring gear backlash and ring gear backface runout. 6. CAUTION: The bearing caps must be installed in their identical locations and positions. Mark each bearing cap before removal. Loosen the differential case. 1 Remove the bearing cap bolts. 2 Remove the bearing caps. 7. To simplify the installation, fabricate two differential case retaining straps from metal stock as shown. 8. WARNING: Be careful not to allow the differential case to fall. CAUTION: Place a wood block between the pry bar and the rear axle housing to protect the machined surface from damage. Use the pry bar and the wood block to remove the differential case from the rear axle housing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5357 9. Remove the ring gear bolts. 10. CAUTION: Care should be taken not to damage the ring bolt hole threads. Note: The anti-lock speed sensor ring cannot be reused once removed. Insert a punch in the bolt holes. Drive off the ring gear and, if necessary, the anti-lock speed sensor ring. 11. Install the differential case. 1 Position the differential case assembly, including bearing cups and shims, in the carder. 2 Install the differential bearing caps. 3 Install the differential bearing cap bolts. 12. Position the special tool. 1 Rotate the differential case to make sure the differential bearings are correctly seated. 2 Position the special tool. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5358 13. Note: If runout is less than specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, replace both the differential case and the differential bearings. Measure the differential case runout without the ring gear. 1 Rotate the differential case. 2 Check and note the differential case runout. 14. Remove the differential case from the rear axle housing, and remove the differential bearings using the special tool. 15. Using the special tool, install the new differential bearings on the differential case. 16. Measure the differential case runout without the ring gear. - Check the case runout again with the new differential bearings. If the runout is now at specification, use the new differential bearings for assembly. If the runout is still excessive, the differential case is damaged and must be replaced. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5359 Installation 1. CAUTION: Make sure that the notches on the case flange and anti-lock speed sensor ring are aligned. Press the ring gear and, if removed, a new anti-lock speed sensor on the differential case. 2. Install the ring gear bolts. - Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts. 3. With pinion depth set and the pinion installed, place the differential case in the rear axle housing. 4. Install a (nominal) shim on the left side. 5. CAUTION: The bearing caps must be installed in their identical locations and positions. Note: Apply pressure toward the left side to make sure the left bearing cap is seated. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5360 - Install the left bearing cap, and loosely install the bearing cap bolts. 6. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand. 7. Install the right side bearing cap, and tighten the bolts. 8. Rotate the differential case to make sure it rotates freely. 9. Using the special tool, measure ring gear backlash. - If the backlash is within specification, go to Step 15. The specification shown is the full allowable range. - If a zero backlash condition occurs, go to Step 10. - If the backlash is not within specification, go to Step 11. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5361 10. If a zero backlash condition occurs, add a 0.50 mm (0.020 inch) shim to the RH side and subtract 0.50 mm (0.020 inch) from the LH side to allow backlash indication. Check backlash. Repeat Step 9. 11. To increase or decrease backlash, remove the bearing caps, and install a thicker shim and a thinner shim as shown. - If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount. 12. Install the bearing caps and bearing cap bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5362 13. Rotate the differential several times to make sure the differential bearings are correctly seated. 14. Using the special tool, recheck the backlash. - If backlash is within specification, go to Step 15. If not, repeat Step 9. - The specification shown is the full allowable range. 15. Remove the bearing caps and bolts. - To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration. - Using the special tool, ensure the differential bearing shims are fully seated and the assembly turns freely. 16. Install the bearing caps and bearing cap bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5363 17. Using the special tool, verify the backlash. 18. Install the axle shafts. Conventional Differential Case and Ring Gear Special Tools Disassembly 1. Remove the differential case. 2. Remove the ring gear bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5364 3. Insert a punch in the bolt holes and drive the ring gear off. 4. Note: The anti-lock speed sensor ring cannot be reused once removed. Remove the anti-lock speed sensor ring. 5. If required, remove the differential bearings with the special tools. 6. Remove the differential pinion shaft lock bolt and the differential pinion shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5365 7. Rotate and remove the differential pinion gears and differential pinion thrust washers. 8. Remove the differential side gears and the differential side gear thrust washers. Assembly 1. Position the differential side gear thrust washers on the differential side gears. - Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A to lubricate the differential side gear thrust washers and the differential side gear journals. 2. Position the differential side gears. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5366 3. Assemble the differential pinion thrust washers and the differential pinion gears. - Lubricate with SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 4. Engage the differential pinion gears opposite the differential side gears. 5. Using the special tool, install the differential bearings. 6. Rotate the differential pinion gears to align the differential pinion shaft bore. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5367 7. Insert the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight. 8. Press the new anti-lock speed sensor ring and the ring gear on the differential case. - The notch on the differential case flange and the notch on the anti-lock speed sensor ring must be aligned. 9. Install the ring gear bolts and tighten. - Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts. 10. Install the differential case. Traction-LOK Differential Case and Ring Gear Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5368 Special Tools Special Tools Disassembly 1. Remove the differential case. 2. Note: The differential bearings need not be removed to overhaul the Ford limited slip differential. If bearing removal is required, use the 2-Jaw Puller and the Step Plate. Note: The anti-lock speed sensor ring cannot be reused once removed. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft. If required, remove the ring gear and anti-lock speed sensor ring. 3. Install the special tool in a suitable vise. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5369 4. Install the differential case on the tool. 5. Note: Apply a small amount of grease to the centering hole of the special tool. Install the special tool in the bottom side gear bore. 6. Install the nut in the upper differential side gear. Hold the nut in position while installing the hex screw. Tighten the hex-head screw until contact is made with the step plate. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5370 7. Note: The dowel bar is used to keep the nut from turning when the forcing screw is tightened. Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential side gear away from the differential pinion gears. 8. WARNING: Keep fingers/hands away from pinion gears when rotating the differential case with the differential rotating tool. Note: Differential pinion thrust washers cannot be removed independently of the differential pinion gears and so must be removed simultaneously with the differential pinion gears Insert the special tool in the pinion shaft bore, and turn the differential case to "walk" the differential pinion gears and differential pinion thrust washers out to the differential case windows. 9. Remove the differential pinion gears and differential pinion thrust washers. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5371 10. Remove the differential side gears and differential clutch packs, and tag them RIGHT and LEFT with the shim. 11. CAUTION: When separating the clutch plates and clutch discs, note the sequence in which they are disassembled. They must be reassembled in the same sequence. CAUTION: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only. Separate the differential clutch discs and clutch plates for cleaning and inspection. Assembly 1. Prelubricate each steel clutch plate and soak all friction plates in Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5372 2. Note: Do not mix the differential clutch packs or shims from one side with the other. Note: The Belleville spring is a dished plate. Assemble the differential clutch packs (without the shims and Belleville springs) on the respective differential side gears. 3. Clamp the bolt head of the special tool in a vise. Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the gauge. 4. Position the special tool on top of the differential clutch pack. 5. Install the special tool over the disc and differential clutch pack. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5373 6. Install the nut of the gauge over the top and base stud. 7. Note: These shims are available as part of Clutch Pack Replacement Kit F75Z-4947-AA. Use the Feeler Gauge and select the thickest blade that will enter between the tool and the differential clutch pack. Subtract 0.010 inch from the reading to obtain the thickness of the new clutch shim. A maximum of two shims may be used. Select the correct shim(s) size and remove the Traction-Lok Clutch Gauge. 8. Place the shim and Belleville spring on the differential clutch pack. - The dished or concave side of the Belleville spring must face up and against the thrust face of the differential case. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5374 9. Insert the differential clutch packs with shims and Belleville springs and differential side gears into the differential case. - Hold the upper clutch pack and side gear assembly in place to prevent it from falling out of the differential case. 10. Note: Apply a small amount of grease to the step plate bore. Note: If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened. Assemble the forcing screw, nut and step plate to the differential case. 1 Position the step plate in the bottom side gear bore. 2 Position the nut in the top side gear bore and hold it in place. 3 Install the hex-head screw and tighten it two turns after it contacts the bottom step plate. 11. Note: Prelubricate both sides of the differential pinion thrust washers with SAE 75W-140 High Performance Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Note: Make sure the differential pinion gears are 180° apart so they will align correctly with the pinion shaft bore. Position the differential pinion gears and differential pinion thrust washers in the window of the differential case so they mesh with the differential side gear teeth. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5375 12. WARNING: Keep fingers/hands away from pinion gears when rotating the differential case with the differential rotating tool. Note: It will probably be necessary to loosen or tighten the forcing screw to allow the differential pinion gears and differential side gears to rotate. Insert the special tool into the pinion shaft bore, and turn the differential case. This will cause the differential pinion gears to engage the differential side gears and "walk" into the differential case. Rotate the differential case until the pinion mating shaft holes are lined up exactly with the holes in the differential pinion gears 13. Loosen the forcing screw, and remove the step plate and nut from the side gear bores. Install the differential pinion shaft in the differential case. - Install a new differential pinion shaft lock bolt finger-tight. 14. Replace the differential bearings, if removed, using the special tool. 15. Check the torque required to rotate one differential side gear. - Install the special tool with the 1/2-inch drive hole as shown. - The initial break-away torque, if original clutch plates are used, must be within specification. The rotating torque required to keep the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Front > Page 5376 differential side gear turning with new clutch plates may vary. 16. Using a press, install the ring gear and, if removed, a new anti-lock speed sensor ring on the differential case and tighten the retaining bolts. - The notch on the differential case flange and the notch on the anti-lock speed sensor ring must be aligned. 17. Install the differential case. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > Customer Interest: > 00-8-4 > Apr > 00 > Differential - Chattering On Turns Differential Clutch: Customer Interest Differential - Chattering On Turns Article No. 00-8-4 DATE: 04/17/2000 ^ NOISE - "CHATTERING" FROM REAR AXLE HEARD ON TURNS OR WHEN CORNERING VEHICLES WITH LIMITED SLIP AXLE ^ AXLE - LIMITED SLIP - REAR AXLE "CHATTERING" NOISE ON TURNS OR WHEN CORNERING FORD: 1999-2000 E-150, EXPEDITION, F-150 LINCOLN: 1999-2000 NAVIGATOR ISSUE A "chattering" noise from the rear axle may be heard when turning or cornering. This may be due to differentials containing clutch packs that have been gauged too tightly. ACTION Install new Traction-Lok Clutch Pack Kit. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Confirm axle chatter with road test. 2. Once axle chatter has been confirmed, remove and discard old clutch packs, shims and Belleville springs. Refer to the appropriate Workshop Manual for details. NOTE: Subtract O.25 mm (0.010") from feeler gauge reading taken during shim selection using service tools and procedures indicated on instruction sheets packaged with kits. 3. Install Clutch Pack Kit F75Z-4947-AA for 9.75" ring gear Traction-Lok axles or Clutch Pack Kit F75Z-4947-AB for 10.25 " ring gear Traction-Lok axles. For ring gear size and differential type, see embossed metal tag attached to rear axle cover. Refer to the appropriate Workshop Manual for details. PART NUMBER PART NAME F752-4947-AA Clutch Pack Kit (9.75" Ring Gear) F75Z-4947-AB Clutch Pack Kit (10.25" Ring Gear) OTHER APPLICABLE ARTICLES: NONE Operation Information Operarion numbers description and times Dealer Coding Dealer part number and condition code Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > Customer Interest: > 00-8-4 > Apr > 00 > Differential - Chattering On Turns > Page 5385 Oasis Coding Oasis codes WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-8-4 > Apr > 00 > Differential - Chattering On Turns Differential Clutch: All Technical Service Bulletins Differential - Chattering On Turns Article No. 00-8-4 DATE: 04/17/2000 ^ NOISE - "CHATTERING" FROM REAR AXLE HEARD ON TURNS OR WHEN CORNERING VEHICLES WITH LIMITED SLIP AXLE ^ AXLE - LIMITED SLIP - REAR AXLE "CHATTERING" NOISE ON TURNS OR WHEN CORNERING FORD: 1999-2000 E-150, EXPEDITION, F-150 LINCOLN: 1999-2000 NAVIGATOR ISSUE A "chattering" noise from the rear axle may be heard when turning or cornering. This may be due to differentials containing clutch packs that have been gauged too tightly. ACTION Install new Traction-Lok Clutch Pack Kit. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Confirm axle chatter with road test. 2. Once axle chatter has been confirmed, remove and discard old clutch packs, shims and Belleville springs. Refer to the appropriate Workshop Manual for details. NOTE: Subtract O.25 mm (0.010") from feeler gauge reading taken during shim selection using service tools and procedures indicated on instruction sheets packaged with kits. 3. Install Clutch Pack Kit F75Z-4947-AA for 9.75" ring gear Traction-Lok axles or Clutch Pack Kit F75Z-4947-AB for 10.25 " ring gear Traction-Lok axles. For ring gear size and differential type, see embossed metal tag attached to rear axle cover. Refer to the appropriate Workshop Manual for details. PART NUMBER PART NAME F752-4947-AA Clutch Pack Kit (9.75" Ring Gear) F75Z-4947-AB Clutch Pack Kit (10.25" Ring Gear) OTHER APPLICABLE ARTICLES: NONE Operation Information Operarion numbers description and times Dealer Coding Dealer part number and condition code Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-8-4 > Apr > 00 > Differential - Chattering On Turns > Page 5391 Oasis Coding Oasis codes WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5397 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5398 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5399 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5400 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5401 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5407 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5408 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5409 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5410 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Differential Clutch: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5411 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Front Differential Cover: Specifications Front General Specifications Differential cover bushing gap ........................................................................................................................................................ 1.93 mm (0.076 inch) Torque Specifications Differential Housing Cover Bushing Bolt ............................................................................................................................................ 89 Nm (66 ft. lbs.) Differential Housing Cover Bolts ........................................................................................................................................................ 32 Nm (24 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications > Front > Page 5416 Differential Cover: Specifications Rear Ford - 8.8 Inch Ring Gear Differential Housing Cover Bolts ............................................................................................................................................................ 45 Nm (33 ft. lbs.) Ford - 9.75 Inch Ring Gear Differential Housing Cover Bolts ........................................................................................................................................................ 45 Nm (33 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8-Inch Ring Gear Differential Cover: Service and Repair 8.8-Inch Ring Gear Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Note: Empty the lubricant into a clean container for reuse. Remove the differential housing cover. 1 Remove the 10 bolts and drain the lubricant from the differential housing. 2 Remove the differential housing cover. Installation 1. CAUTION: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the new silicone sealant. Cover the inside of the axle before cleaning the machined surface to prevent contamination. Clean the differential housing cover and differential housing gasket mating surface. 2. CAUTION: Install the differential housing cover within 15 minutes of applying the silicone material. Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface. Use Clear Silicone Rubber F7AZ-19554-CA or equivalent meeting Ford specification ESB-M4G92-A. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5419 3. CAUTION: Allow the sealant to cure for one hour before filling the axle with lubricant. Install the differential housing cover. 1 Position the differential housing cover. 2 Install the 10 bolts. 4. CAUTION: For Traction-Lok axles, first fill the rear axle with 118 ml (4 oz) of Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A. Note: Service refill capacities are determined by filling the rear axle with the specified lubricant 6.4 14.3 mm (0.25 - 0.57 inch) below the bottom of the filler hole. Fill the rear axle with 2.5 - 2.6 liters (5.25 - 5.50 pints) of SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A and install the filler plug. 5. Note: If equipped with air suspension, reactivate the system. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5420 Differential Cover: Service and Repair 9.75-Inch Ring Gear Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Position the rear stabilizer bar and rear axle tracking bar aside. 3. Note: Empty the lubricant into a clean container for reuse. Remove the differential housing cover. 1 Remove the 12 differential housing cover bolts and drain the lubricant from the rear axle housing. 2 Remove the differential housing cover Installation 1. CAUTION: Make sure the machined surfaces on both the rear axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination. Clean the gasket mating surface of the rear axle and the differential housing cover 2. Apply a new, continuous bead of sealant to the differential housing cover. - Use Clear Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification E1SB-M4G392-A. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 5421 3. Note: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow 1 hour before filling with lubricant to ensure the silicone sealant has properly cured. Install the differential housing cover and tighten the differential housing cover bolts. 4. Note: Service refill capacities are determined by filling the rear axle with the specified lubricant to the specified level below the bottom of the filler hole. Fill the rear axle with specified lubricant, and install the filler plug. For Traction-lok axles, first fill the rear axle with 118 ml (4 ounces) of specified Ford Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A. 5. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Specifications Differential Axle Housing: Specifications Rear Axle Housing Vent ............................................................................................................................................................. 11-24 Nm (8-18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Casting Porosity (Holes In Casting) Repair Differential Axle Housing: Service and Repair Casting Porosity (Holes In Casting) Repair CAUTION: To keep the axle's sound characteristics, do not disassemble the carrier. Note: Casting porosity is a condition where occasionally gas bubbles will form during the casting process leaving small pockets in the metal that will cause the axle housing to leak. 1. To fill small pockets, peen in a small amount of body lead. 2. Seal the pocket. - Use Devcon Aluminum Liquid F2 or equivalent meeting Ford specification M-3D35A(E). 3. To fill large pockets, drill and tap a shallow hole for a small setscrew. Install the setscrew and seal it. - Use Devcon Aluminum Liquid F2 or equivalent meeting Ford specification M-3D35A(E). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Casting Porosity (Holes In Casting) Repair > Page 5427 Differential Axle Housing: Service and Repair Weld Leaks Repair 1. CAUTION: To keep the axle's sound characteristics, do not disassemble the carrier. 2. CAUTION: Rear axle housing straightness is too critical for field repair. Install a new axle housing if a weld is broken. Note: Most minor weld leaks are repairable. This includes the puddle and fill welds that join the axle shaft tube to the axle housing on integral axles. Seal the weld. Use Devcon Aluminum Liquid F2 or equivalent meeting Ford specification M-3D35A(E). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Drain Plug, Differential > Component Information > Specifications Drain Plug: Specifications Drain Plug (Front) ................................................................................................................................ ............................................... 25 Nm (18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component Information > Specifications > Front Fill Plug: Specifications Front Fill Plug ................................................................................................................................................ ................................................... 25 Nm (18 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component Information > Specifications > Front > Page 5435 Fill Plug: Specifications Rear Ford - 8.8 Inch Ring Gear Oil Filler Plug ....................................................................................................................................... ............................................... 30 Nm (22 ft. lbs.) Ford - 9.75 Inch Ring Gear Oil Filler Plug ....................................................................................................................................... ................................................... 30 Nm (22 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front Differential Oil Capacity Refill ..................................................................................................................................................... ..................................................................... 1.8-2.0L Rear Differential Oil Capacity Refill ..................................................................................................................................................... ..................................................................... 2.9-3.1L Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 5440 Fluid - Differential: Fluid Type Specifications Front Differential Fluid Type Motorcraft SAE 75W-90 Premium 4x4 Front Axle Lubricant XY-75W90-TQL Specification ............... .............................................................................................................................................................. ................. WSP-M2C201-A Rear Differential Fluid Type Type .................................................................................................................................................. SAE 75W140 High Performance Rear Axle Lubricant Additive Friction Modifier ................................ .......................................................................................................................................... C8AZ-19B546-A Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Front Pinion Bearing: Specifications Pinion Bearing Torque Preload (Used Pinion Bearing) 8 - 14 in.lb Pinion Bearing Torque Preload (New Pinion Bearing) 16 - 29 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Front > Page 5445 Pinion Bearing: Specifications Rear Pinion Bearing Preload (Used Pinion Bearings) 8 - 14 in.lb Pinion Bearing Preload (New Pinion Bearings) 16 - 29 in.lb Pinion Bearing Preload (Used Pinion Bearing) 8 - 14 in.lb Pinion Bearing Preload (New Pinion Bearing) 16 - 29 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Specifications > Ford - 8.8 Inch Ring Gear Pinion Flange: Specifications Ford - 8.8 Inch Ring Gear Pinion flange maximum runout ............................................................................................................ ................................................... 0.25 (0.010 T.I.R.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Specifications > Ford - 8.8 Inch Ring Gear > Page 5450 Pinion Flange: Specifications Ford - 9.75 Inch Ring Gear Pinion flange maximum radial runout in assembly .............................................................................................................................................................. ........................ 0.305 mm (0.012 T.I.R. inch) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Pinion Flange: Service and Repair Front Special Tools Removal WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. CAUTION: This operation disturbs the pinion bearing preload. Carefully reset the preload during assembly. Note: The front drive axle must be in NEUTRAL before beginning this procedure 1. Raise and support the vehicle. 2. Remove the front differential support. 1 Remove the nut and bolt. 2 Remove the nuts and bolts. 3 Remove the front differential support. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front > Page 5453 3. Index-mark the front driveshaft to the axle universal joint flange. 4. CAUTION: Do not allow the driveshaft to hang unsupported. Disconnect and support the front driveshaft. 1 Remove the four bolts. 2 Carefully disconnect and support the front driveshaft. 5. Using a Nm (inch/pound) torque wrench, measure the torque necessary to maintain pinion rotation. Record the measurement for reference during installation. 6. Index-mark the axle universal joint flange to the pinion stem. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front > Page 5454 7. Install the special tool, and loosen, but do not remove the pinion nut. 8. CAUTION: Before proceeding, place a drain pan under the differential carrier. With the pinion nut still engaged by a few threads, use the special tool to separate the axle universal joint flange from the pinion gear. 9. Remove the nut and the flange. 10. Inspect the axle universal joint flange for burrs, the nut counterbore and the seal contact surface for nicks, and the bearing cone contact area for damage. Install a new flange if necessary. 11. Check the pinion stem splines for burrs. If burrs are evident, remove them with a fine crocus cloth. Working in a rotating motion, wipe the pinion clean. Installation 1. Lubricate the axle universal joint flange splines and the pinion seal. - Use Motorcraft SAE 75W-90 Premium 4x4 Front Axle Lubricant XY-75W90-TQL or equivalent meeting Ford specification WSP-M2C201-A. 2. CAUTION: Never install the axle universal joint flange with a hammer or power tools. Note: Disregard the scribe marks if installing a new flange. Align the index-marks and position the axle universal joint flange on the pinion shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front > Page 5455 3. Note: Rotate the pinion gear occasionally to make sure the pinion bearings seat correctly. Using the special tool, install the axle universal joint flange. 4. CAUTION: Do not loosen the pinion nut to reduce preload under any circumstance. If it is necessary to reduce preload, install a new drive pinion collapsible spacer and pinion nut. Install the special tool, and tighten the pinion nut. Rotate the pinion gear occasionally to make sure the pinion bearings are seating correctly. Take frequent pinion bearing torque preload readings by rotating the pinion gear with a Nm (inch/pound) torque wrench. - If the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the pinion nut to the specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the pinion nut to the original reading as recorded. 5. Align the index-marks then attach the front driveshaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front > Page 5456 6. Install the front differential support. 7. Inspect and, if necessary, fill the differential. - Use Motorcraft SAE 75W-90 Premium 4x4 Front Axle Lubricant XY-75W9O-TQI or equivalent meeting Ford specification WSP-M2C201-A. 8. Lower the vehicle. 9. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front > Page 5457 Pinion Flange: Service and Repair Rear Ford 8.8 - Inch Ring Gear Special Tools Removal CAUTION: Remove the rear wheel and tire assemblies, brake calipers, and brake discs to prevent brake drag during the drive pinion bearing preload adjustment. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle 2 Remove the rear wheel and tire assemblies. 3. CAUTION: Do not allow the brake caliper to hang from the brake hose. Provide a suitable support. Remove the rear brake calipers, and the brake discs. Position the brake calipers aside. 4. Index-mark the driveshaft flange and pinion flange to maintain initial balance during installation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front > Page 5458 5. Remove the four bolts and disconnect the driveshaft. Wire the driveshaft out of the way. 6. Install a Nm (inch-pound) torque wrench on the nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions. 7. CAUTION: After removing the nut, discard it. Use a new nut for installation. Use the special tool to hold the pinion flange while removing the nut. 8. Index-mark the pinion flange and the drive pinion gear stem to maintain initial balance during installation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front > Page 5459 9. Using the special tool, remove the pinion flange. Installation 1. Lubricate the pinion flange splines. - Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Note: Disregard the index marks if installing a new pinion flange. Position the pinion flanges 3. Using the special tool, install the pinion flange. 4. Position the new nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front > Page 5460 5. CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce preload, install a new drive pinion collapsible spacer and nut. CAUTION: Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench. Use the special tool to hold the pinion flange while tightening the nut. Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent pinion bearing torque preload readings by rotating the drive pinion gear with a Nm (inch/pound) torque wrench. - If the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the nut to the original reading as recorded. 6. CAUTION: Align the index-marks. Connect the driveshaft. 7. Install the rear brake discs, and the brake calipers. 8. Install the rear wheel and tire assemblies. 9. Note: If equipped with air suspension, reactivate the system. Lower the vehicle. Ford 9.75-Inch Ring Gear Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front > Page 5461 Special Tools Removal 1. Note: The rear wheels and brake discs must be removed to prevent brake drag during drive pinion bearing preload adjustment. Remove the brake discs. 2. Mark the driveshaft flange and pinion flange for correct alignment during installation. 3. Remove the four driveshaft bolts, and disconnect the driveshaft. Wire the driveshaft out of the way. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front > Page 5462 4. Install a torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions. 5. CAUTION: After removal of the pinion nut, discard it. A new nut must be used for installation. Using a suitable flange holding tool to hold the pinion flange while removing the pinion nut. 6. Mark the driveshaft rear axle pinion flange in relation to the drive pinion stem to ensure correct alignment during installation. 7. Using the special tool, remove the pinion flange. Installation 1. Lubricate the pinion flange splines. - Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front > Page 5463 2. Note: Disregard the scribe marks if a new pinion flange is being installed. Align the rear axle pinion flange with the drive pinion shaft. 3. With the drive pinion in place in the axle housing, install the pinion flange using the special tool. 4. Position the new pinion nut. 5. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed. CAUTION: Remove the suitable pinion flange holding tool while taking preload readings with the Nm (inch-pound) torque wrench. Using a suitable pinion flange holding tool, hold the pinion flange, tighten the pinion nut. Rotate the pinion occasionally to make sure the cone and roller bearings are seating correctly. - Install a Nm (inch-pound) torque wrench on the pinion nut. - Rotating the pinion through several revolutions, take frequent cone and roller bearing torque preload readings until the original recorded Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front > Page 5464 preload reading is obtained. - If the original recorded preload is lower than specifications, tighten to the appropriate specification for used bearings. If the preload is higher than specification, tighten the nut to the original reading as recorded. 6. Position the driveshaft, and align the marks on the pinion flange. 7. Install the four bolts. 8. Install the brake discs. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear Pinion Gear: Service and Repair Ford 8.8-Inch Ring Gear Special Tools Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5469 Special Tools Removal 1. Remove the differential case. 2. CAUTION: Record the torque necessary to maintain rotation of the drive pinion gear through several revolutions prior to removing the pinion flange. Remove the pinion flange. 3. Using a screwdriver, force the rear axle drive pinion seal metal flange up and strike it with a hammer. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5470 4. Using gripping pliers and a hammer, remove the rear axle drive pinion seal. 5. Remove the rear axle drive pinion shaft oil slinger. 6. Using the special tool and a soft-faced hammer, drive the pin assembly out of the front pinion bearing and remove it through the rear of the differential housing. 7. Remove the drive pinion collapsible spacer and discard it. 8. Using the special tool and a suitable press, remove the pinion bearing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5471 9. Note: Do not remove the pinion bearing cups from the differential housing unless the cups are damaged. Using the special tools, remove the outer pinion bearing cup. 10. Using the special tools, remove the inner pinion bearing cup. Installation 1. Note: This step and the following step show the preferred method for installing the pinion bearing cups. An alternate method is shown following these two steps. Position the special tools and the inner and outer pinion bearing cups in their respective bores. 1 After placing the inner and outer bearing cups in their bores, place the special tool on the inner bearing cup. 2 Place the special tool on the outer bearing cup. 3 Install the special tool into the replacer tools. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5472 2. Tighten the special tool to seat the pinion bearing cups into their bores. 3. Note: This step and the following step are alternate methods for installing the pinion bearing cups. Carry out these two steps if pinion bearing cup installation was not done in the previous steps. Using the special tools, drive the outer pinion bearing cup into the differential housing. 4. Using the special tools, drive the inner pinion bearing cup into the differential housing. 5. CAUTION: Always install new pinion bearings when installing new pinion bearing cups. Note: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup. Check that the cups have seated correctly in their bores. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5473 6. Note: Apply only a light oil film on the pinion bearings before assembling the tool. Assemble and position the following in the differential housing. 7. Note: This step duplicates final pinion bearing preload. Tighten the special tool to the specification shown. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5474 8. CAUTION: Offset the special tool to obtain an accurate reading. Rotate the special tool several half-turns to make sure the pinion bearings seat correctly and position the special tool as shown. 9. Install the special tool. 1 Position the special tool. 2 Install the bearing caps. 3 Install the bolts. 10. CAUTION: Use only flat, clean drive pinion bearing adjustment shims. CAUTION: Selection of too thick a shim results in a deep tooth contact at final assembly. Do not attempt to force the shim between the Gauge Block and the Gauge Tube. A slight drag indicates correct shim selection. Use a drive pinion bearing adjustment shim as a gauge for shim selection. After determining the correct shim thickness, remove the special tools. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5475 11. Position the correct thickness drive pinion bearing adjustment shim and the pinion bearing on the drive pinion gear. Using a suitable press and the special tools, press the pinion bearing until it seats firmly on the pinion. 12. Place a new drive pinion collapsible spacer on the drive pinion gear shaft against the pinion stem shoulder. 13. CAUTION: Installation without the correct tool can result in early seal failure. Install a new rear axle drive pinion seal. 1 Install the front pinion bearing. 2 Install the rear axle drive pinion shaft oil slinger. 3 Position the rear axle drive pinion seal on the special tool. 14. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the seal and install a new seal. Note: Coat the rear axle drive pinion seal lips with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Position the rear axle drive pinion seal in the seal bore, and use the special tool to drive the seal into place. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5476 15. From inside the differential housing, install the drive pinion assembly (drive pinion, shims, bearing, and the collapsible spacer) into the carrier bore. 16. Lubricate the pinion flange splines. - Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 17. Note: Disregard the index marks if installing a new pinion flange. Position the pinion flange. 18. Using the special tool, install the pinion flange. 19. Position the new nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5477 20. CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce preload, install a new drive pinion collapsible spacer and nut. CAUTION: Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench. Use the special tool to hold the pinion flange while tightening the nut. Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench. - For new pinion bearings, tighten the nut to specification. - For used pinion bearings, if the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the nut to specification. - For used pinion bearings, if the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the nut to the original reading as recorded. 21. Install the differential case in the differential housing. 22. Install the driveshaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5478 Pinion Gear: Service and Repair Ford 9.75-Inch Ring Gear Special Tools Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5479 Special Tools Removal 1. Remove the differential case. 2. Mark the driveshaft flange and the pinion flange for correct alignment during installation. 3. Remove the four driveshaft bolts, and disconnect the driveshaft. - Wire the driveshaft out of the way. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5480 4. Using a suitable pinion flange holding tool, remove the pinion nut. 5. Remove the pinion flange using the special tool. - Remove the rear axle drive pinion seal. 6. Remove the rear axle drive pinion shaft oil slinger. 7. Install the special tool and, with a soft-faced hammer, drive the pinion out of the front bearing cone and remove it through the rear of the housing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5481 8. Remove the drive pinion collapsible spacer and discard it. 9. Using the special tool, remove the pinion bearing cone and roller assembly. 10. Note: Do not remove the pinion bearing cups from the housing unless the cups are damaged. Remove the outer differential bearing cup with the special tools. 11. Remove the inner differential bearing cup with the special tools. Installation Using 205-024 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5482 1. Position the special tools and the inner and outer bearing cups in their respective bores. 1 After placing the inner and outer bearing cups in their bores, place the special tool (inner) on the inner pinion bearing cup. 2 Place the special tool (outer) on the outer pinion bearing cup. 3 Install the special tool. 2. Tighten the special tool to seat the pinion bearing cups into their bores. Using 205-D055 3. Drive the outer pinion bearing cup into the rear axle housing, using the special tools. 4. Drive the inner pinion bearing cup into the rear axle housing, using the special tools. Setting pinion depth Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5483 5. CAUTION: Whenever new cups are installed, new differential pinion bearings must also be installed. Make sure the cups are correctly seated in their bores. If a feeler gauge of the specification shown in the illustration can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated. 6. Note: Apply only a light oil film on the pinion bearings before assembling the tool. Assemble and position the Pinion Depth Gauge Set. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5484 7. Note: This step duplicates final pinion bearing preload. Tighten the Handle to the specification. 8. Note: The special tool must be offset to obtain an accurate reading. Rotate the special tool several half-turns to ensure correct seating of the pinion bearings, and position the special tool. 9. Install the special tool. 1 Position the special tool. 2 Install the differential side bearing caps. 3 Install the differential side bearing cap bolts. 10. Note: Drive pinion bearing adjustment shims must be flat and clean. Note: A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the Gauge Block and the Gauge Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5485 Tube. This will minimize selection of a pinion shim thicker than required, which results in a deep tooth contact in the final assembly of integral rear axle assemblies. Use a drive pinion bearing adjustment shim as a gauge for shim selection. After the correct shim thickness has been determined, remove the special tools from the rear axle housing. 11. Using a press and the special tool, press the pinion bearing and pinion shim until they are firmly seated on the pinion. 12. Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder. 13. CAUTION: Installation without the correct tool can result in early seal failure. If the rear axle drive pinion seal becomes cocked during installation, remove it and install a new one. Install a new rear axle drive pinion seal 1 Install the outer pinion bearing cone and roller. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5486 2 Install the rear axle drive pinion shaft oil slinger in the rear axle housing. 3 Install the rear axle drive pinion seal on the special tool. 14. Note: Coat the lips of the rear axle drive pinion seal with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Use a hammer to install the bearing, rear axle drive pinion seal and rear axle drive pinion shaft oil slinger. 15. Install the drive pinion in the drive pinion bore from inside the rear axle housing. Seat the drive pinion with a plastic hammer. 16. Lubricate the pinion flange splines. - Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 17. Note: Disregard the scribe marks if a new pinion flange is being installed. Align the pinion flange with the drive pinion shaft. 18. With the drive pinion in place in the rear axle housing, install the pinion flange using the special tool. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5487 19. Position the new pinion nut. 20. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed. CAUTION: Remove the suitable pinion flange holder while taking preload readings with the Nm (inch-pound) torque wrench. Using a suitable pinion flange holding tool, hold the pinion flange, tighten the pinion nut. Rotate the pinion occasionally to make sure the cone and roller bearings are seating correctly. - Install a Nm (inch-pound) torque wrench on the pinion nut. - Rotating the pinion through several revolutions, take frequent cone and roller bearing torque preload readings until the original recorded preload reading is obtained. 21. Install the differential case. 22. Install the driveshaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Front Ring Gear: Specifications Front General Specifications Ring gear backlash .............................................................................................................................................................. ............. 0.203-0.381 mm (0.008-0.015 inch) preferred ............................................................................................................................................................. 0.305-0.381 mm (0.012-0.015 inch) Ring gear maximum backface runout .............................................................................................................................................................. ........... 0.102-0.004 mm (0.004-0.0001 inch) Torque Specifications Ring Gear Bolts ................................................................................................................................... .............................................. 105 Nm (77 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Front > Page 5492 Ring Gear: Specifications Rear Ford - 8.8. Inch Ring Gear Clearance, Tolerance and Adjustments Maximum back face ring gear runout ........................................................................................................................................... 0.102 mm (0.004 inch) Backlash between ring gear and pinion teeth .............................................................................................................................................................. ............. 0.203-0.381 (0.305-0.381 preferred) ..................................................................................... ...................................................................................... 0.008-0.015 (0.012-0.015 preferred) Ring gear maximum backlash variation between teeth ................................................................................................................. 0.102 mm (0.004 inch) Torque Specifications Ring Gear Bolts ................................................................................................................................... .............................................. 105 Nm (77 ft. lbs.) Ford - 9.75 Inch Ring Gear Clearance, Tolerance and Adjustments Maximum back face ring gear runout ........................................................................................................................................... 0.102 mm (0.004 inch) Backlash between ring gear and pinion teeth ........................................................................................................................................................... 0.203-0.381 mm (0.008-0.015 inch) maximum ............................................................................................................................................................ 0.305-0.381 mm (0.012-0.015 inch) preferred Ring gear maximum backlash variation between teeth .............................................................................................................................................................. .................................. 0.102 mm (0.004 inch) Torque Specifications Ring Gear Bolts ................................................................................................................................... ............................................ 150 Nm (111 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional Differential Case and Ring Gear Ring Gear: Service and Repair Conventional Differential Case and Ring Gear Special Tools Disassembly 1. Remove the differential assembly from the differential housing. 2. Remove the bolts. 3. CAUTION: Do not damage the differential ring gear bolt hole threads. CAUTION: If removing the anti-lock speed sensor ring, discard it, and install a new anti-lock speed sensor ring during assembly. Insert a punch in the bolt holes, and drive off the differential ring gear and, if necessary, the anti-lock speed sensor ring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional Differential Case and Ring Gear > Page 5495 4. Using the special tools, remove the differential bearings, if necessary. 5. Remove the bolt. 6. Remove the differential pinion shaft. 7. Rotate and remove the differential pinion gears and differential pinion thrust washers. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional Differential Case and Ring Gear > Page 5496 8. Remove the differential side gears and differential side gear thrust washers. Assembly 1. Lubricate the differential side gear thrust washers and the differential side gear journals. - Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Position the differential side gear thrust washers on the differential side gears. 3. Position the differential side gear and thrust washer assemblies in the differential case. 4. Lubricate and assemble the differential pinion thrust washers and differential pinion gears. - Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional Differential Case and Ring Gear > Page 5497 5. Engage the differential pinion gears opposite the differential side gears. 6. Rotate the differential pinion gears to align with the differential pinion shaft bore. 7. Insert the differential pinion shaft. - Align the bolt hole in the differential pinion shaft with the bolt hole in the differential case. 8. Note: If a new bolt is unavailable, coat the threads with Threadlock and Sealer E0AZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation. Install a new bolt finger-tight. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional Differential Case and Ring Gear > Page 5498 9. Using the special tool, install the new differential bearings. 10. CAUTION: If installing a new anti-rock speed sensor ring, align the notch on the case flange and the tab on the anti-lock speed sensor ring. Position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the differential case. 11. Install the bolts. - Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the bolt threads. 12. Install the differential assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional Differential Case and Ring Gear > Page 5499 Ring Gear: Service and Repair Traction-LOK Differential Case and Ring Gear Special Tools Disassembly 1. Remove the differential assembly from the differential housing. 2. Remove the bolts. 3. CAUTION: Do not damage the bolt hole threads. CAUTION: If removing the anti-lock speed sensor ring, discard it, and install a new anti-lock speed sensor ring during assembly. Insert a punch in the bolt holes, and drive off the differential ring gear and, if necessary, the anti-lock speed sensor ring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional Differential Case and Ring Gear > Page 5500 4. Using the special tools, remove the differential bearings. 5. Remove the bolt and remove the differential pinion shaft. 6. WARNING: Due to the spring tension, use care when removing the differential clutch spring. Failure to follow these instructions may result in personal injury. Remove the differential clutch spring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional Differential Case and Ring Gear > Page 5501 7. Remove the differential gears. 1 Remove the two differential pinion gears. 2 Remove the two differential side gears. 3 Remove the two differential pinion thrust washers. 8. CAUTION: Keep the differential clutch packs in order. Do not mix them. Always reassemble them in the same sequence. Separate the differential clutch packs and shims from the differential side gears and tag them "right" and "left." Clean and inspect the remaining differential components for wear and damage and install new parts as necessary. 9. CAUTION: Do not use acids or solvents when cleaning the differential clutch packs. Wipe the components only with a clean, lint-free cloth. Clean and inspect the differential clutch packs for wear and damage and install new parts as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional Differential Case and Ring Gear > Page 5502 Assembly 1. CAUTION: 118 ml (4 oz) of the Additive Friction Modifier must be used in the axle. Lubricate each steel clutch plate and soak all the friction plates for no less than 15 minutes. Use Additive Friction Modifier C8AZ-13B546-A or equivalent meeting Ford specification EST-M2C118-A 2. CAUTION: Do not mix the clutch plates, clutch discs or shim from one side with the other. Assemble the differential clutch packs (without the shims) on their respective differential side gear. 3. CAUTION: Use the correct mandrel with the special tool. Place the base portion of the special tool in a vise. Install the differential side gear and differential clutch pack (without the shim) on the tool. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional Differential Case and Ring Gear > Page 5503 4. Position the special tool hand-tight on top of the differential clutch pack. 5. Install the special tool over the disc and differential clutch pack. 6. Install the nut. 7. Select and insert the thickest feeler gauge blade that will enter between the tool and the differential clutch pack. The reading will be the thickness Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional Differential Case and Ring Gear > Page 5504 of the new clutch shim. 8. Remove the special tools from the differential clutch pack and differential side gear assembly. 9. Install the shim(s) on the differential clutch pack and differential side gear assembly. 10. Install the differential side gear assemblies in the differential case. 11. Install the differential pinion gear and differential pinion thrust washer assemblies in the differential case. 12. Using a soft-faced hammer, install the differential clutch spring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional Differential Case and Ring Gear > Page 5505 13. Note: If a new bolt is unavailable, coat the threads with Threadlock and Sealer E0AZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation. Install the differential pinion shaft and install a new bolt finger-tight. 14. Mount the differential case and the special tool in a vise. Using the special tool, check the torque necessary to rotate one differential side gear. - If reusing the original clutch plates, the initial minimum break-away torque must be no less than the specification. The minimum rotating torque necessary to keep the differential side gear turning with new clutch plates may vary. 15. Using the special tool, install the differential bearings. 16. CAUTION: If installing a new anti-lock speed sensor ring, align the notch on the case Range and the tab on the anti-lock speed sensor ring. Position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the differential case. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Conventional Differential Case and Ring Gear > Page 5506 17. Install the bolts. - Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to bolt threads. 18. Install the differential assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Seals and Gaskets: Service and Repair Front Special Tools Removal 1. Remove the front axle universal joint flange. 2. CAUTION: Do not damage the front axle housing. Remove the pinion seal. Installation 1. Clean the pinion seal bore, and use the Pinion Seal Replacer to install the pinion seal. 2. Install the from axle universal joint flange. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front > Page 5511 Seals and Gaskets: Service and Repair Rear Ford 8.8 - Inch Ring Gear Special Tools Removal 1. Remove the pinion flange. 2. Using a screwdriver, force the rear axle drive pinion seal metal flange up and strike it with a hammer. 3. Using gripping pliers and a hammer, remove the rear axle drive pinion seal. Installation 1. Lubricate the new rear axle drive pinion seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the rear axle drive pinion seal and replace with a new seal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front > Page 5512 Using the special tool, install the rear axle drive pinion seal. 3. Install the pinion flange. Ford 9.75 - Inch Ring Gear Special Tools Removal 1. Remove the pinion flange. 2. Force up on the metal flange of the pinion seal. Install gripping pliers and strike with a hammer until the pinion seal is removed. Installation 1. Lubricate the new rear axle drive pinion seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the seal and install a new seal. Using the special tool, install the rear axle drive pinion seal. 3. Install the pinion flange. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Axle Shaft Assembly, Constant Velocity Type Axle Shaft: Specifications Axle Shaft Assembly, Constant Velocity Type Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Axle Shaft Assembly, Constant Velocity Type > Page 5519 Axle Shaft: Specifications Axle Shaft, Conventional Fixed/Floating Maximum axle shaft end play 0.030 in Maximum axle shaft end play 0.030 in Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 5520 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 5521 Axle Shaft: Description and Operation New halfshaft components are available as follows: A repair kit includes the boots, clamps, snap ring, retaining ring, and grease. - A new inboard CV joint (plunge type). - A new outboard CV joint and interconnecting shaft assembly includes the outboard front wheel halfshaft joint (fixed type), boot, clamps, and the front wheel excluder seal (assembled on the joint). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type Axle Shaft: Service and Repair Axle Shaft Assembly, Constant Velocity Type Disassembly and Assembly Special Tools Disassembly 1. Remove the halfshaft from the vehicle. 2. CAUTION: Do not damage the boot. Remove the boot clamps. 3. Separate the boot from the inboard CV joint housing. 4. Remove the retaining ring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5524 5. Remove the inboard CV joint housing. 6. Index-mark the inner race and ball cage. 7. Remove the six balls. 8. Remove the snap ring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5525 9. Remove the inner race and the ball cage. 10. Remove the inboard boot. 11. Remove the boot clamps. 12. Remove the outboard boot. 13. Note: If the grease is contaminated, clean and inspect the joint for wear. Install a new outboard CV joint and interconnecting shaft assembly if worn/damaged. Check the grease for contamination. Assembly Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5526 1. Position the outboard boot on the shaft. 2. Pack the outboard CV joint with 165 grams (5.82 ounces) of grease. 1 Use High Temp Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207-A provided in the boot kit. 2 Spread any remaining grease from the kit evenly inside the boot. 3. install the outboard boot. 1 Clean the boot mounting surface. 2 Seat the boot in the joint boot groove. 4. Position the boot clamps. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5527 5. Note: Tighten the through-bolt until the tool is in the closed position. Using the special tool, install the two boot clamps. 6. Position the boot clamp on the shaft. 7. Position the inboard boot on the shaft. 8. Position the ball cage on the shaft with the tapered end facing the boot. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5528 9. Note: Align the index marks. Position the inner race on the shaft with the counterbored end facing the boot. 10. Install the snap ring. 11. Lubricate and position the six balls. - Use High Temp Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207-A provided in the boot kit. 12. Fill the inboard CV joint housing with 235 grams (8.29 ounces) of grease. - Use High Temp Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207-A provided in the boot kit. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5529 13. Position the boot clamp on the inboard CV joint housing. 14. Position the inboard CV joint housing on the ball and race assembly. 15. Install the retaining ring. 16. Remove any excess grease from the matins surface. Seat the boot in the joint boot groove. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5530 17. Set the halfshaft assembled length to specification. 18. CAUTION: Do not damage the boot. Insert a dull screwdriver blade under the boot to release the pressure. 19. Note: Tighten the through-bolt until the tool is in the closed position. Using the special tool, install the two boot clamps. 20. Install the halfshaft in the vehicle. Removal and Installation Special Tools Removal and Installation 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5531 Raise and support the vehicle. 2. Remove the front wheel and tire assembly. 3. Remove the fastener. 1 Remove and discard the cotter pin. 2 Remove the retainer. 3 Remove the nut. 4. CAUTION: Do not allow the front disc brake caliper to hang from the brake hose. Provide a suitable support. Position the front disc brake caliper aside. 1 Remove the bolts. 2 Lift the caliper from the anchor plate and position it aside. 5. Remove the nut. 1 Remove and discard the cotter pin. 2 Remove the nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5532 6. Using the special tool, separate the front wheel knuckle from the front suspension upper arm. 7. Remove the six bolts. 8. CAUTION: Do not damage the hub seal. Separate the halfshaft from the axle and the hub, and remove the assembly from the vehicle. 9. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5533 Axle Shaft: Service and Repair Axle Shaft, Conventional Fixed/Floating Ford 8.8-Inch Ring Gear Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the rear wheel and tire assembly. 3. CAUTION: Do not allow the brake caliper to hang from the brake hose. Provide a suitable support. Remove the rear brake caliper, and the brake disc. Position the brake caliper aside. 4. Remove the differential housing cover - Drain the lubricant. 5. Remove the differential pinion shaft. 1 Remove and discard the differential pinion shaft lock bolt. 2 Remove the differential pinion shaft. 6. CAUTION: Do not damage the rubber O-ring in the U-washer groove. Remove the U-washer. 1 Push the axle shaft inboard. 2 Remove the U-washer. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5534 7. CAUTION: Do not damage the wheel bearing oil seal. Remove the axle shaft. Installation 1. Lubricate the lip of the wheel bearing oil seal. - Use Premium Long-Life Grease XC-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: Do not damage the wheel bearing oil seal. Install the axle shaft. 3. CAUTION: Do not damage the rubber O-ring in the axle shaft groove. Install the U-washer. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5535 1 Position the U-washer on the button end of the axle shaft. 2 Pull the axle shaft outward. 4. Note: If a new differential pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer E0AZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation. Install the differential pinion shaft. 1 Align the hole in the differential pinion shaft with the case lock bolt hole. 2 Install a new differential pinion shaft lock bolt. 5. Install the differential housing cover, and fill the differential housing with the correct amount of specified lubricant. 6. Install the brake disc, and the brake caliper. 7. Install the wheel and tire assembly. 8. Note: If equipped with air suspension, reactivate the system. Lower the vehicle. Ford 9.75-Inch Ring Gear Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the differential housing cover. - Drain the lubricant. 4. Remove the brake calipers and discs. 5. Remove the differential pinion shaft. 1 Remove and discard the differential pinion shaft lock bolt. 2 Remove the differential pinion shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5536 6. CAUTION: Do not damage the rubber O-rings in the axle shaft grooves. Remove the U-washers. 1 Push the axle shafts inboard. 2 Remove the U-washers. 7. CAUTION: Do not damage the wheel bearing oil seal. Remove the two axle shafts. Installation 1. Lubricate the lip of the wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: Do not damage the wheel bearing oil seal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 5537 Install the two axle shafts. 3. CAUTION: Do not damage the rubber O-rings in the U-washer grooves. Install the U-washers. 1 Position the two U-washers on the button ends of the axle shafts. 2 Pull the axle shafts outward. 4. Note: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer E0AZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation. Install the differential pinion shaft. 1 Align the hole in the differential pinion shaft with the case lock bolt hole. 2 Install a new differential pinion shaft lock bolt. 5. Install the brake discs. 6. Install the differential housing cover and fill the rear axle housing with the correct amount of specified lubricant. 7. Install the tire and wheel assembly. 8. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Ford 8.8-Inch Ring Gear Seals and Gaskets: Service and Repair Ford 8.8-Inch Ring Gear Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. 3. Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing, and the wheel bearing oil seal. Installation 1. Lubricate the new rear wheel bearing. - Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5542 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5543 Seals and Gaskets: Service and Repair Ford 9.75-Inch Ring Gear Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing and wheel bearing oil seal. Installation 1. Lubricate the new rear axle bearing. - Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Ford 8.8-Inch Ring Gear > Page 5544 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal 5. Install the axle shafts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricate the new rear wheel bearing. - Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 5548 Wheel Bearing: Testing and Inspection Wheel Bearing Check 1. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Spin the tire by hand to check the wheel bearings for roughness. NOTE: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 5549 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate service procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Ford Wheel Bearing: Service and Repair Ford Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. 3. Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing, and the wheel bearing oil seal. Installation 1. Lubricate the new rear wheel bearing. - Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Ford > Page 5552 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Ford > Page 5553 Wheel Bearing: Service and Repair Front Removal Note: The wheel bearing and hub are installed as an assembly. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and wheel bearings. Remove the wheel and tire assembly. 3. Remove the brake disc. 4. Remove the front wheel hub nut. 1. Remove and discard the cotter pin. 2. Remove the retainer. 3. Remove the nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Ford > Page 5554 5. Remove the brake disc shield. 1. Remove the bolts. 2. Remove the brake disc shield. 6. Remove the front brake anti-lock sensor. 1. Remove the bolt. 2. Remove the front brake anti-lock sensor. 7. CAUTION: Do not over-extend the CV joint and boots when removing the hub and bearing assembly. Note: The CV joint is a slip fit into the wheel hub and bearing. A puller will not normally be required. Remove the wheel hub. 1. Remove the bolts. 2. Push the CV joint inboard. Remove the wheel hub. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Ford > Page 5555 8. Remove the seal. Installation 1. Install the seal using the Knuckle Seal Replacer, the Threaded Drawbar and Bearing Cup Replacer. 2. Install the wheel hub. 1. Position the wheel hub on the front wheel driveshaft and joint and into the front wheel knuckle. 2. Install the wheel hub bolts. 3. Install the front brake anti-lock sensor. 1. Install the front brake anti-lock sensor into the wheel hub. 2. Install the front brake anti-lock sensor bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Ford > Page 5556 4. Install the brake disc shield and front axle hub nut. 1. Position the brake disc shield. 2. Install the bolts. 3. Install the front axle hub nut. 4. Install the retainer. 5. Install a new cotter pin. 5. Install the brake disc. 6. WARNING: When the wheel is installed, always remove any corrosion, dirt or foreign material that may be present on the mounting surfaces of the wheels or the surfaces of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can cause the wheel nut to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. WARNING: ^ Retighten at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened. ^ Failure to retighten wheel nuts at the mileage specified could allow wheels to come off while the vehicle is in motion, possibly causing loss of vehicle control and collision. Install the tire and wheel assembly. 7. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Hub Nut .............................................................................................................................. ................................. 255-345 Nm (188-254 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > General Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > General Specifications > Page 5566 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Double Cardan Rear Driveshaft - 4X4 Without Air Suspension Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Double Cardan Rear Driveshaft - 4X4 Without Air Suspension > Page 5569 Drive/Propeller Shaft: Diagrams Driveshaft 1 of 2 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Diagrams > Double Cardan Rear Driveshaft - 4X4 Without Air Suspension > Page 5570 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Universal Joints Drive/Propeller Shaft: Description and Operation Universal Joints The universal joints (U-joints) connect to each end of the driveshaft and allow for up and down movement of the axles and transmission or transfer case. The U-joints are lubricated for the life of the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation > Universal Joints > Page 5573 Drive/Propeller Shaft: Description and Operation Driveshaft CAUTION: All driveshafts are balanced. If undercoating the vehicle, protect the driveshaft and universal joints to prevent application of any undercoating material. Note: Refer to driveshaft runout and balance, and indexing procedures. Driveshafts differ in length, diameter, and type of slip yoke to accommodate various wheelbase and powertrain combinations. The rear driveshaft is connected to the pinion flange by a driveshaft flange yoke with four bolts. It is connected to the transmission or transfer case with a driveshaft slip yoke. The front driveshaft is connected to the transfer case and the front drive axle by flanges. Inspect the driveshaft slip yoke rubber boot for rips and holes. Install new components as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 Removal and Installation 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Failure to follow these instructions may result in personal injury. With the vehicle in neutral, raise and support the vehicle. 2. Remove the front driveshaft shield. 3. Index-mark the front flange and pinion flange. - Repeat for the rear flange and transfer case flange. 4. Remove the four bolts retaining the rear flange to the transfer case. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft-Front > Page 5576 5. Remove the four bolts retaining the front flange to the pinion flange. 6. Remove the front driveshaft. 7. CAUTION: If new bolts to retain the driveshaft to the axle and the driveshaft to the transfer case are not available, coat the threads of the original bolts with Threadlock and Sealer E0AZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5. To install reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Driveshaft-Front > Page 5577 Drive/Propeller Shaft: Service and Repair Driveshaft-Rear Removal and Installation 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Failure to follow these instructions may result in personal injury. With the vehicle in neutral, raise and support the vehicle 2. Index-mark the driveshaft flange yoke and pinion flange 3. Index-mark the driveshaft and the extension housing. 4. Remove the four bolts. 5. Disconnect the driveshaft flange yoke from the pinion flange. Lower the driveshaft and slide it off of the output shaft. 6. Plug the extension housing to prevent fluid loss. 7. CAUTION: If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with Threadlock and Sealer E0AZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Service and Repair Slip Yoke: Service and Repair Special Tools Disassembly 1. CAUTION: Do not clamp the driveshaft in the jaws of a vise or similar holding fixture. Remove the driveshaft slip yoke boot. 1 With the front driveshaft on a bench, cut and discard the driveshaft slip yoke boot clamps. 2 Separate the driveshaft slip yoke from the splined stub shaft on the driveshaft. 2. Remove the driveshaft slip yoke boot. - Inspect the driveshaft slip yoke boot for damage and install a new boot, if necessary. - Inspect the lubricant for contamination. If contaminated, disassemble the driveshaft and inspect the stub shaft and driveshaft slip yoke for wear. Install new components as needed. Assembly 1. Slide the small opening end of the driveshaft slip yoke boot on the splined stub shaft as far as it will travel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Service and Repair > Page 5581 2. Install the driveshaft slip yoke boot clamp and use Keystone Clamp Pliers to crimp the driveshaft slip yoke boot clamp. 3. Install the driveshaft slip yoke. 1 Lubricate the stub shaft splines, and pull the driveshaft slip yoke boot towards the driveshaft. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2 Fill the driveshaft slip yoke boot with approximately 10 grams of lubricant. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 3 Position the large driveshaft slip yoke boot clamp. 4 Align the blind splines, and install the driveshaft slip yoke. 4. Install the large driveshaft slip yoke boot clamp. 1 Remove any excess grease from the driveshaft slip yoke boot and driveshaft slip yoke surfaces. 2 Position the driveshaft slip yoke boot over the driveshaft slip yoke boot groove. 3 Position the driveshaft slip yoke to specification from the driveshaft weld to the U-joint centerline. 4 Bleed air from the driveshaft slip yoke boot. 5 Use Keystone Clamp Pliers to crimp the large driveshaft slip yoke boot clamp. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Double Cardan Universal Joint: Service and Repair Double Cardan Special Tools Disassembly 1. Remove the driveshaft. 2. CAUTION: Do not clamp the driveshaft in a vise or similar holding fixture. Place the driveshaft on a suitable workbench. 3. Note: If components are not marked and installed correctly, driveline imbalance can occur. Mark the positions of the driveshaft components. 4. Clamp the C Frame & Screw in a vise. 5. Remove the eight snap rings. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Double Cardan > Page 5586 6. Remove the driveshaft slip yoke. 1 Position the driveshaft slip yoke in the C Frame & Screw. 2 Press out the bearing cups. 3 Remove the driveshaft slip yoke. 7. Press out the second set of bearing cups. 1 Position the driveshaft slip yoke in the C Frame & Screw. 2 Press out the bearing cup. 3 Rotate the driveshaft slip yoke. 4 Press out the remaining bearing cup. 8. Remove the centering cup spring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Double Cardan > Page 5587 9. Remove the driveshaft center yoke. 1 Position the driveshaft center yoke in the C Frame & Screw. 2 Press out the bearing cup. 3 Rotate the driveshaft center yoke. 4 Press out the remaining bearing cup. - Repeat to remove the spider from the driveshaft yoke. Assembly 1. Install a new bearing cup into the driveshaft yoke. 1 Start a new bearing cup into the driveshaft yoke. 2 Position the new spider in the driveshaft yoke. 3 Position the driveshaft in the C Frame & Screw. 4 Press the bearing cup below the yoke surface. Repeat for the other side of the yoke. 2. Install the driveshaft center yoke. 1 Position the driveshaft center yoke in the C Frame & Screw. 2 Press in a new bearing cup. 3 Rotate the driveshaft center yoke. 4 Press in the other new bearing cup. 3. Install four new snap rings. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Double Cardan > Page 5588 4. Install a new centering cup spring. 5. Install new bearing cups into the driveshaft yokes. 1 Start a new bearing cup into the driveshaft yoke. 2 Position the new spider in the driveshaft yoke. 3 Position the driveshaft in the C Frame & Screw. 4 Press the bearing cup below the yoke surface. 6. Install four new snap rings. 7. Note: Do not strike the bearings. Check the U-joints for freedom of movement. If bearings are binding, strike the yoke with a plastic hammer. 8. Install the driveshaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Double Cardan > Page 5589 Universal Joint: Service and Repair Universal Joint -Single Cardan Special Tools Disassembly 1. Remove the driveshaft. 2. CAUTION: Do not clamp the driveshaft in the jaws of a vise or similar holding fixture. Place the driveshaft on a suitable workbench, being careful not to damage the tube. 3. Note: If components are not marked and installed incorrectly, driveline imbalance can occur. Mark the positions of the driveshaft components. 4. Clamp the C Frame & Screw in a vise. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Double Cardan > Page 5590 5. Remove the snap rings. 6. Note: If necessary, use a pair of pliers to remove a bearing cup if it cannot be pressed out all the way. Remove the driveshaft slip yoke. 1 Position the driveshaft slip yoke in the C Frame & Screw. 2 Press out a bearing cup. 3 Rotate the driveshaft slip yoke. 4 Press on the spider to remove the remaining bearing cup. Remove the driveshaft slip yoke. 7. Repeat the previous step to remove the remaining bearing cups, spiders and driveshaft flange yoke from the driveshaft. 8. Clean the yoke area at each end of the driveshaft. Assembly 1. Install the bearing cup. 1 Start a new bearing cup into the driveshaft yoke. 2 Position the new spider in the driveshaft yoke. 3 Position the driveshaft in the C Frame & Clamp. 4 Press the bearing cup below the yoke surface. 2. Note: Use the yellow snap rings supplied in the kit to assemble the universal joint (U-joint). If difficulty is encountered with the yellow snap rings, install the black snap rings. Remove the driveshaft from the C Frame & Screw, and install the snap ring. 3. Repeat the two previous steps for the opposite side of the driveshaft yoke. 4. Repeat the previous steps to install the remaining new bearing cups, spider, driveshaft slip yoke, driveshaft flange yoke and snap rings. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Double Cardan > Page 5591 5. Note: Do not strike the bearings. Check the U-joints for freedom of movement. If binding, strike the yoke with a brass or plastic hammer. 6. Install the driveshaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flywheel bolts 54 - 64 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 5595 Flex Plate: Service and Repair Removal 1. Remove the transmission. 2. Remove the bolts. Installation 1. Position the flywheel and install the bolts tighten the bolts in two stages. - Stage 1: Loosely install the bolts - Stage 2: Tighten the bolts in sequence shown. 2. Install the transmission. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission control selector lever in the (D) position. - Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D) position). 3. Hang an eight pound weight on the transmission control selector lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the shift control selector lever from detent to detent and compare with transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 5610 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 5616 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5627 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5628 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5634 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5635 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5638 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5639 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5640 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5641 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5642 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5643 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5644 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5645 Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5646 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5647 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5648 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5649 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5650 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5651 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque on Demand Relay Four Wheel Drive Selector Relay: Locations Torque on Demand Relay The Torque on Demand relay is located behind the center of the Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque on Demand Relay > Page 5656 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay The Torque on Demand relay is located behind the center of the Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque on Demand Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque on Demand Relay > Page 5659 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation Transmission Control Switch Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 5665 Transmission Mode Switch: Service and Repair Removal 1. Remove the Transmission Control (TC) switch. 1 Remove the TC switch cover. 2 Remove the TC switch. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission TR Sensor 71 - 88 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5669 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > 4R70W Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > 4R70W > Page 5672 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 5673 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 5674 Digital Transmission Range Sensor: Service and Repair Special Tools Removal 1. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If this concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 5675 5. Remove the digital Transmission Range (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. Installation 1. Install the digital Transmission Range (TR) sensor. 1 Install digital Transmission Range (TR) sensor. 2 Loosely install the bolts. 2. Note: Make sure that the manual control lever is in the neutral position. Install the TRS Alignment Gauge. The TRS Alignment Gauge is designed to fit snug. 3. Tighten the bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 5676 4. Reconnect the shift cable at the manual control lever. 5. Reconnect the connector. 6. Lower the vehicle. 7. Reconnect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 71 - 88 in.lb Turbine Shaft Speed (TSS) Sensor Bolt 71 - 88 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5680 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Output Shaft Speed (OSS) Sensor > Page 5683 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5684 Transmission Speed Sensor: Service and Repair Removal 1. Remove the drive shaft. 2. Remove the rear transmission mount nuts. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Remove the rear transmission mount. 1 Raise the transmission up off the rear crossmember support. 2 Remove the bolts. 3 Remove the rear transmission mount. 4. Lower the transmission to gain access to the Turbine Shaft Speed (TSS) sensor, and the Output Shaft Speed (OSS) sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5685 5. Remove the Turbine Shaft Sensor (TSS). 1 Remove the bolt. 2 Remove the Turbine Shaft Sensor (TSS). 6. Remove the Output Shaft Speed (OSS) sensor. 1 Remove the bolt. 2 Remove the Output Shaft Speed (OSS) sensor. Installation 1. Install the Output Shaft Speed (OSS) sensor. 1 Lubricate the O-ring and install the Output Shaft Speed (OSS) sensor. 2 Install the bolt. 2. Install the Turbine Shaft Sensor (TSS). 1 Lubricate the O-ring and install the Turbine Shaft Sensor (TSS). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5686 2 Install the bolt. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the sensors will occur. Install the rear transmission mount. 1 Raise the transmission up. 2 Install the rear transmission mount. 3 Install the bolts. 4. Lower the transmission on to the rear crossmember support. 5. Install the rear transmission mount nuts. 6. Install the drive shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 5691 Four Wheel Drive Selector Switch: Description and Operation 4x4 Mode Switch Typical 4x4 Switch The Generic Electronic Module (GEM) provides the PCM with an indication of 4x4L. This input is used to adjust the shift schedule. A 5.0 volt module pull-up indicates 4x4H or 4x2. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 5692 Four Wheel Drive Selector Switch: Service and Repair Removal 1. Remove the center instrument panel trim panel. 2. Remove the shift range selector switch. 1 Remove the switch knob. 2 Disconnect the electrical connector. 3 Remove the bolts. 4 Remove the shift range selector switch. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications Output Speed Sensor Bolt 44 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Front Output Shaft Speed Sensor Speed Sensor: Service and Repair Front Output Shaft Speed Sensor Removal 1. Remove the transfer case shift motor. 2. Remove the wire connector spacer and the front output shaft speed sensor wire pins from the electrical connector. - Use the proper electrical connector pin remover. 3. Remove the front output shaft speed sensor. 1 Remove the bolt. 2 Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats net against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Front Output Shaft Speed Sensor > Page 5698 Speed Sensor: Service and Repair Rear Output Shaft Speed Sensor Removal WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air spring, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the wire connector spacer and the rear output shaft speed sensor wire pins from the electrical connector. - Use the proper electrical connector pin remover. 4. Remove the bolt, and remove the sensor. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Front Output Shaft Speed Sensor > Page 5699 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications Shift Motor Bolts .................................................................................................................................. ................................................. 10 Nm (89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5705 Transfer Case Actuator: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the coil wire pin from the electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire pin. - Use proper electrical connector pin remover. 4. CAUTION: Note each sensor wire pin location for correct installation. Remove the front and rear output shaft speed sensor wire pins from the electrical connector. Use the proper electrical connector pin remover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5706 5. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Case: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Case: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Case: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5715 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Case: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5716 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Case: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5722 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5723 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Page 5724 Case: Specifications Transfer Case Bolts 18 ft.lb Transmission-To-Transfer Case Bolts 35 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts Control Module: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts > Page 5733 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts > Page 5734 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5740 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5741 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5744 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5745 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5746 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5747 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5748 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5749 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5750 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5751 Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5752 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5753 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5754 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5755 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5756 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5757 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Capacity ....................................................................................................................... .................................................................... 2.0 Quarts Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 5762 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid Type ..................................................................................................................................................... ............................................................. Mercon ATF Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 5771 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 5777 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque on Demand Relay Four Wheel Drive Selector Relay: Locations Torque on Demand Relay The Torque on Demand relay is located behind the center of the Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque on Demand Relay > Page 5782 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay The Torque on Demand relay is located behind the center of the Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque on Demand Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque on Demand Relay > Page 5785 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 5789 Four Wheel Drive Selector Switch: Description and Operation 4x4 Mode Switch Typical 4x4 Switch The Generic Electronic Module (GEM) provides the PCM with an indication of 4x4L. This input is used to adjust the shift schedule. A 5.0 volt module pull-up indicates 4x4H or 4x2. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 5790 Four Wheel Drive Selector Switch: Service and Repair Removal 1. Remove the center instrument panel trim panel. 2. Remove the shift range selector switch. 1 Remove the switch knob. 2 Disconnect the electrical connector. 3 Remove the bolts. 4 Remove the shift range selector switch. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 5800 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 5806 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Four Wheel Drive Indicator Lamp: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5826 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5827 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5833 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5834 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5837 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5838 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5839 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5840 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5841 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5842 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5843 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5844 Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5845 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5846 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5847 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5848 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5849 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 5850 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque on Demand Relay Four Wheel Drive Selector Relay: Locations Torque on Demand Relay The Torque on Demand relay is located behind the center of the Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque on Demand Relay > Page 5855 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay The Torque on Demand relay is located behind the center of the Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque on Demand Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque on Demand Relay > Page 5858 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair Seals and Gaskets: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Note: Index-mark the rear driveshaft yoke and pinion flange to maintain initial driveshaft balance during installation. Remove the rear driveshaft. 3. Using a suitable tool, remove the oil seal. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Page 5862 - Using the special tool, install the oil seal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 5867 Four Wheel Drive Selector Switch: Description and Operation 4x4 Mode Switch Typical 4x4 Switch The Generic Electronic Module (GEM) provides the PCM with an indication of 4x4L. This input is used to adjust the shift schedule. A 5.0 volt module pull-up indicates 4x4H or 4x2. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 5868 Four Wheel Drive Selector Switch: Service and Repair Removal 1. Remove the center instrument panel trim panel. 2. Remove the shift range selector switch. 1 Remove the switch knob. 2 Disconnect the electrical connector. 3 Remove the bolts. 4 Remove the shift range selector switch. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications Output Speed Sensor Bolt 44 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Front Output Shaft Speed Sensor Speed Sensor: Service and Repair Front Output Shaft Speed Sensor Removal 1. Remove the transfer case shift motor. 2. Remove the wire connector spacer and the front output shaft speed sensor wire pins from the electrical connector. - Use the proper electrical connector pin remover. 3. Remove the front output shaft speed sensor. 1 Remove the bolt. 2 Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats net against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Front Output Shaft Speed Sensor > Page 5874 Speed Sensor: Service and Repair Rear Output Shaft Speed Sensor Removal WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air spring, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the wire connector spacer and the rear output shaft speed sensor wire pins from the electrical connector. - Use the proper electrical connector pin remover. 4. Remove the bolt, and remove the sensor. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Front Output Shaft Speed Sensor > Page 5875 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications Output Speed Sensor Bolt 44 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Front Output Shaft Speed Sensor Speed Sensor: Service and Repair Front Output Shaft Speed Sensor Removal 1. Remove the transfer case shift motor. 2. Remove the wire connector spacer and the front output shaft speed sensor wire pins from the electrical connector. - Use the proper electrical connector pin remover. 3. Remove the front output shaft speed sensor. 1 Remove the bolt. 2 Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats net against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Front Output Shaft Speed Sensor > Page 5881 Speed Sensor: Service and Repair Rear Output Shaft Speed Sensor Removal WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air spring, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the wire connector spacer and the rear output shaft speed sensor wire pins from the electrical connector. - Use the proper electrical connector pin remover. 4. Remove the bolt, and remove the sensor. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Front Output Shaft Speed Sensor > Page 5882 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications Shift Motor Bolts .................................................................................................................................. ................................................. 10 Nm (89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5886 Transfer Case Actuator: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the coil wire pin from the electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire pin. - Use proper electrical connector pin remover. 4. CAUTION: Note each sensor wire pin location for correct installation. Remove the front and rear output shaft speed sensor wire pins from the electrical connector. Use the proper electrical connector pin remover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5887 5. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications Shift Lock Actuator: Specifications Shift Lock Actuator Bolts 62.5 - 98 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Lock Actuator <--> [Shift Interlock Solenoid] > Component Information > Specifications > Page 5894 Shift Lock Actuator: Service and Repair Removal 1. Remove the steering column. 2. Remove the insert plate and shift lock actuator. 1 Remove the bolts. 2 Remove the insert plate and shift lock actuator. 3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications Shift Motor Bolts .................................................................................................................................. ................................................. 10 Nm (89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5899 Transfer Case Actuator: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the coil wire pin from the electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire pin. - Use proper electrical connector pin remover. 4. CAUTION: Note each sensor wire pin location for correct installation. Remove the front and rear output shaft speed sensor wire pins from the electrical connector. Use the proper electrical connector pin remover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5900 5. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission control selector lever in the (D) position. - Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D) position). 3. Hang an eight pound weight on the transmission control selector lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the shift control selector lever from detent to detent and compare with transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 5915 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 5921 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5932 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5933 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts Control Module: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts > Page 5939 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts > Page 5940 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 02-10-8 > May > 02 > Fuel System - Whistling Noise Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Fuel System - Whistling Noise Article No. 02-10-8 05/27/02 ^ DRIVEABILITY - 5.4L 2V - IDLE-AIR BYPASS FLOW INDUCED WHISTLE ^ ENGINE - 5.4L 2V - IDLE-AIR BYPASS FLOW INDUCED WHISTLE ^ NOISE - IDLE-AIR BYPASS FLOW INDUCED WHISTLE - VEHICLES EQUIPPED WITH 5.4L 2V ENGINE ONLY FORD: 1999-2002 E SERIES, EXPEDITION, F-150, SUPER DUTY F SERIES ISSUE Some vehicles equipped with the 5.4L 2V engine may exhibit a "whistling" noise from the formed nylon tube in the idle-air bypass flow circuit. This may be caused by air flow passing through the sharp bend radius of the original tube assembly. ACTION Remove and replace formed nylon tube with the Nipple And Hose Assembly 2L1Z-9W548-AA. This action will correct the sharp bend in the tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the formed tube as shown (Figure 1). 2. Replace with Nipple And Hose Assembly with part 2L1Z-9W548-AA. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 02-10-8 > May > 02 > Fuel System - Whistling Noise > Page 5946 3. Connect nipple to the air-inlet zip tube and the free end connects to resonator as shown (Figure 2). 4. Ensure that there are no kinks in the rubber hose which could restrict air flow. LABOR OPERATION CLAIMING CHART PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9H308 V3 OASIS CODES: 497000, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 02-10-8 > May > 02 > Fuel System - Whistling Noise > Page 5952 3. Connect nipple to the air-inlet zip tube and the free end connects to resonator as shown (Figure 2). 4. Ensure that there are no kinks in the rubber hose which could restrict air flow. LABOR OPERATION CLAIMING CHART PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9H308 V3 OASIS CODES: 497000, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 5955 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 5956 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 5957 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 5958 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 5959 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 5960 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 5961 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 5962 Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 5963 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 5964 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 5965 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 5966 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 5967 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Diagram Information and Instructions > Page 5968 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque on Demand Relay Four Wheel Drive Selector Relay: Locations Torque on Demand Relay The Torque on Demand relay is located behind the center of the Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations > Torque on Demand Relay > Page 5973 Four Wheel Drive Selector Relay: Locations Transfer Case Shift Relay The Torque on Demand relay is located behind the center of the Instrument Panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque on Demand Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Torque on Demand Relay > Page 5976 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation Transmission Control Switch Transmission Control Switch (TCS) Transmission Control Switch (TCS) The Transmission Control Switch (TCS) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 5982 Transmission Mode Switch: Service and Repair Removal 1. Remove the Transmission Control (TC) switch. 1 Remove the TC switch cover. 2 Remove the TC switch. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications Digital Transmission Range Sensor: Specifications Digital Transmission TR Sensor 71 - 88 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5986 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > 4R70W Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > 4R70W > Page 5989 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 5990 Digital Transmission Range Sensor: Description and Operation Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches The Clutch Pedal Position (CPP) switch is an input to the PCM indicating the clutch pedal position and, in some manual transmission applications, both the clutch pedal engagement position and the gear shift position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed, indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 5991 Digital Transmission Range Sensor: Service and Repair Special Tools Removal 1. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If this concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 5992 5. Remove the digital Transmission Range (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. Installation 1. Install the digital Transmission Range (TR) sensor. 1 Install digital Transmission Range (TR) sensor. 2 Loosely install the bolts. 2. Note: Make sure that the manual control lever is in the neutral position. Install the TRS Alignment Gauge. The TRS Alignment Gauge is designed to fit snug. 3. Tighten the bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Diagrams > Page 5993 4. Reconnect the shift cable at the manual control lever. 5. Reconnect the connector. 6. Lower the vehicle. 7. Reconnect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications Output Shaft Speed (OSS) Sensor Bolt 71 - 88 in.lb Turbine Shaft Speed (TSS) Sensor Bolt 71 - 88 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 5997 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Output Shaft Speed (OSS) Sensor Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 > Output Shaft Speed (OSS) Sensor > Page 6000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6001 Transmission Speed Sensor: Service and Repair Removal 1. Remove the drive shaft. 2. Remove the rear transmission mount nuts. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Remove the rear transmission mount. 1 Raise the transmission up off the rear crossmember support. 2 Remove the bolts. 3 Remove the rear transmission mount. 4. Lower the transmission to gain access to the Turbine Shaft Speed (TSS) sensor, and the Output Shaft Speed (OSS) sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6002 5. Remove the Turbine Shaft Sensor (TSS). 1 Remove the bolt. 2 Remove the Turbine Shaft Sensor (TSS). 6. Remove the Output Shaft Speed (OSS) sensor. 1 Remove the bolt. 2 Remove the Output Shaft Speed (OSS) sensor. Installation 1. Install the Output Shaft Speed (OSS) sensor. 1 Lubricate the O-ring and install the Output Shaft Speed (OSS) sensor. 2 Install the bolt. 2. Install the Turbine Shaft Sensor (TSS). 1 Lubricate the O-ring and install the Turbine Shaft Sensor (TSS). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6003 2 Install the bolt. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the sensors will occur. Install the rear transmission mount. 1 Raise the transmission up. 2 Install the rear transmission mount. 3 Install the bolts. 4. Lower the transmission on to the rear crossmember support. 5. Install the rear transmission mount nuts. 6. Install the drive shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 6008 Four Wheel Drive Selector Switch: Description and Operation 4x4 Mode Switch Typical 4x4 Switch The Generic Electronic Module (GEM) provides the PCM with an indication of 4x4L. This input is used to adjust the shift schedule. A 5.0 volt module pull-up indicates 4x4H or 4x2. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 6009 Four Wheel Drive Selector Switch: Service and Repair Removal 1. Remove the center instrument panel trim panel. 2. Remove the shift range selector switch. 1 Remove the switch knob. 2 Disconnect the electrical connector. 3 Remove the bolts. 4 Remove the shift range selector switch. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications Output Speed Sensor Bolt 44 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Front Output Shaft Speed Sensor Speed Sensor: Service and Repair Front Output Shaft Speed Sensor Removal 1. Remove the transfer case shift motor. 2. Remove the wire connector spacer and the front output shaft speed sensor wire pins from the electrical connector. - Use the proper electrical connector pin remover. 3. Remove the front output shaft speed sensor. 1 Remove the bolt. 2 Remove the front output shaft speed sensor. Installation 1. CAUTION: Make sure the sensor seats net against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Front Output Shaft Speed Sensor > Page 6015 Speed Sensor: Service and Repair Rear Output Shaft Speed Sensor Removal WARNING: The electrical power supply to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air spring, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the wire connector spacer and the rear output shaft speed sensor wire pins from the electrical connector. - Use the proper electrical connector pin remover. 4. Remove the bolt, and remove the sensor. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Front Output Shaft Speed Sensor > Page 6016 1. CAUTION: Make sure the sensor seats flat against the boss. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Differential Speed Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications Anti-lock brake control module screws 44 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 6025 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 6026 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 6027 Electronic Brake Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 6028 Electronic Brake Control Module: Service and Repair Removal and Installation 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Disconnect the anti-lock brake control module electrical connector. 3. Disconnect the pump motor electrical connector from the anti-lock brake control module. 4. Remove the screws and the anti-lock brake control module. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Electronic hydraulic control unit (EHCU) bracket bolts to frame 22 ft.lb Electronic hydraulic control unit (EHCU) bolts to bracket 26 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6032 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6033 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal and Installation 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery negative cable. 2. Disconnect the anti-lock brake control module electrical connector. 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, Hush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Only Ford authorized inlet hydraulic brake tubes should be used. These tubes are of specific design and only Ford authorized parts should be used when installing new inlet brake tubes. Note: Plug each open port to prevent brake fluid from spilling. Disconnect the hydraulic brake tubes. 4. Remove the bolts and the hydraulic control unit (HCU). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6034 5. If necessary, remove the bolts and the HCU bracket. 6. To install, reverse the removal procedure. 7. Bleed the brake system. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front anti-lock brake sensor bolt 63 - 80 in.lb Rear anti-lock brake sensor bolt 20 ft.lb Anti-lock brake sensor screws 89 - 123 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Right Front Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Right Front > Page 6040 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front Wheel Speed Sensor: Service and Repair Sensor, Front Removal 1. Disconnect the front brake anti-lock sensor electrical connector. 2. Remove the front disc brake rotor shield. 3. Remove the (A) front brake anti-lock sensor bolts and the (B) front brake anti-lock sensor. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 6043 Wheel Speed Sensor: Service and Repair Sensor, Rear Removal 1. Raise and support vehicle. 2. Note: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1. Disconnect the rear anti-lock brake sensor electrical connector. 2. Remove the bolt. 3. Remove the rear anti-lock brake sensor. Installation 1. Note: Thoroughly clean the mounting surface. Note: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with SAE-75W-140 High Performance Rear Axle Lubricant FITZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Front disc brake caliper bleeder screw 9 - 13 ft.lb Front master cylinder brake tube 17 - 20 ft.lb Rear disc brake caliper bleeder screw 12 - 18 ft.lb Rear master cylinder brake tube 11 - 14 ft.lb Wheel cylinder bleeder screw 63 - 80 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed Brake Bleeding: Service and Repair Brake Master Cylinder - Bench Bleed WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with specified brake fluid. ^ Use High Performance DOT 3 Brake Fluid C6AZ-1 9542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir. 3. Slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles. 4. Remove the short brake tubes. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6049 Brake Bleeding: Service and Repair Brake Master Cylinder - In-Vehicle Bleed Special Tools WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Note: When a new brake master cylinder has been installed or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. Disconnect the brake master cylinder outlet tubes. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6050 2. Install short brake tubes with ends submerged in the brake master cylinder reservoir and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes without air bubbles. 4. Remove the short brake tubes and install the brake outlet tubes. 5. Bleed each brake tube at the brake master cylinder as follows: 1. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 2. Loosen the rear most brake tube fittings until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the brake tube fitting. 3. Repeat this operation until clear, bubble-free fluid comes out. 4. Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. 6. While the assistant maintains pressure on the brake pedal, tighten the brake tubes. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6051 Brake Bleeding: Service and Repair Brake System Gravity Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. Note: When a new brake master cylinder has been installed or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. 1. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Bleed the rear disc brake calipers. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. 2. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. ^ Repeat for LH rear disc brake caliper. 3. Tighten the rear disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6052 4. Bleed the front disc brake calipers. 1. Place a box end wrench on the RH front disc brake caliper bleeder screw. 2. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. ^ Repeat for LH front disc brake caliper. 5. Tighten the front disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6053 Brake Bleeding: Service and Repair Brake System Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. 5. Repeat Steps 1, 2, 3, and 4 for the LH rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6054 6. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 7. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 8. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 9. Tighten the RH front disc brake caliper bleeder screw. 10. Repeat Steps 6, 7, 8, and 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6055 Brake Bleeding: Service and Repair Brake Master Cylinder - Bench Bleed WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with specified brake fluid. ^ Use High Performance DOT 3 Brake Fluid C6AZ-1 9542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir. 3. Slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles. 4. Remove the short brake tubes. Brake Master Cylinder - In-Vehicle Bleed Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6056 Special Tools WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Note: When a new brake master cylinder has been installed or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. Disconnect the brake master cylinder outlet tubes. 2. Install short brake tubes with ends submerged in the brake master cylinder reservoir and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes without air bubbles. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6057 4. Remove the short brake tubes and install the brake outlet tubes. 5. Bleed each brake tube at the brake master cylinder as follows: 1. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 2. Loosen the rear most brake tube fittings until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the brake tube fitting. 3. Repeat this operation until clear, bubble-free fluid comes out. 4. Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. 6. While the assistant maintains pressure on the brake pedal, tighten the brake tubes. Brake System Gravity Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. Note: When a new brake master cylinder has been installed or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. 1. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Bleed the rear disc brake calipers. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. 2. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. ^ Repeat for LH rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6058 3. Tighten the rear disc brake caliper bleeder screws. 4. Bleed the front disc brake calipers. 1. Place a box end wrench on the RH front disc brake caliper bleeder screw. 2. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. ^ Repeat for LH front disc brake caliper. 5. Tighten the front disc brake caliper bleeder screws. Brake System Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6059 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. 5. Repeat Steps 1, 2, 3, and 4 for the LH rear disc brake caliper. 6. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 7. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 8. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6060 9. Tighten the RH front disc brake caliper bleeder screw. 10. Repeat Steps 6, 7, 8, and 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Brake System Pressure Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. Note: Bleed the longest line first. Be sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. Note: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6061 3. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the rear disc brake caliper bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten rear disc brake caliper bleeder screw and remove the rubber hose. 6. Continue bleeding the rest of the system, going in order from the LH rear disc brake caliper to the RH front disc brake caliper (213121) ending with the LH front disc brake caliper. 7. Close the bleeder tank valve and remove the tank hose from the adapter and remove the adapter. 8. Fill the brake master cylinder reservoir and install the brake master cylinder filler cap. Four Wheel Antilock Brake System Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. Note: This procedure must be performed if the 4 wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been installed new. Note: One conventional pressure bleed cycle consists of advancing the brake pedal to its depressed position, opening the disc brake caliper bleeder screw, allowing fluid to be released into the waste container, closing the disc brake caliper bleeder screw and releasing the brake pedal. Note: Performing the NGS program routine drives entrapped air from the otherwise inaccessible lower section of the 4WABS valve into the upper sections (accessible by bleeding the brakes). Subsequent bleedings remove the air from the system. Note: Add recommended brake fluid as necessary throughout the procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6062 1. Connect a clear waste line to the RH rear disc brake caliper bleeder screw and the other end in a container partially filled with recommended brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. 5. Repeat Steps 1, 2, 3, and 4 for the LH rear disc brake caliper bleeder screw, RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw. 6. Note: Go to the help menu in the scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6063 Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the dash and follow the scan tool instructions. 7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal feels spongy, repeat the scan tool service bleed procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Page 6064 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Brake pedal bracket nuts and bolt 16 - 21 ft.lb Brake pedal bracket nuts and bolts (adjustable pedal) 19 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions Brake Pedal Assy: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 6070 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 6071 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 6072 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 6073 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 6074 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 6075 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 6076 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 6077 Brake Pedal Assy: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 6078 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 6079 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 6080 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 6081 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 6082 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 6083 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 6084 Brake Pedal Assy: Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 6085 Brake Pedal Assy: Electrical Diagrams Diagram 127-1 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 6086 Diagram 127-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Diagram Information and Instructions > Page 6087 Diagram 127-3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Diagrams > Page 6088 Brake Pedal Assy: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Brakes and Traction Control; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal Brake Pedal Assy: Service and Repair Brake Pedal Removal 1. CAUTION: The brake pedal and the accelerator pedal must be in the same position when installing a new cable or a new pedal. The pedals must be in the all the way forward or all the way rearward position. Disconnect the battery ground cable. 2. Remove the instrument panel opening cover. 3. Remove the stoplight switch self-locking pin. 4. Slide the stoplight switch, booster push rod and the bushing off the brake pedal pin. 5. Remove the brake pedal-to-accelerator pedal cable from the accelerator pedal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal > Page 6091 6. Disconnect the brake pedal motor electrical connector. 7. Unload the pedal spring. 8. Remove the brake pedal nut. 9. Remove the brake pedal bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal > Page 6092 10. Remove the brake pedal. Installation 1. Install the brake pedal. 2. Make sure bushings are in the end of the pivot tube. 3. Install the brake pedal bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal > Page 6093 4. Install the brake pedal nut. 5. Load the pedal spring. 6. Connect the brake pedal motor electrical connector. 7. Install the brake pedal-to-accelerator pedal cable in the accelerator pedal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal > Page 6094 8. CAUTION: When installing the brake pedal-to-accelerator pedal cable, the brake pedal and the accelerator pedal must be in the same position, all the way forward or all the way rearward. Position the accelerator pedal using the brake pedal motor, all the way forward or backward depending on the position of the new brake pedal. 9. Remove the brake pedal-to-accelerator pedal cable from the accelerator pedal, by pulling on the cable retainer. 10. Position the brake pedal in the same position as the accelerator pedal, using the brake pedal motor. 11. Install the brake pedal-to-accelerator pedal cable in the accelerator pedal. 12. If installing a new accelerator pedal, the accelerator pedal will come in the forward or rearward position. Before installing the cable, move the brake pedal with the motor so it is in the same position as the accelerator pedal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal > Page 6095 13. Slide the stoplight switch, booster push rod and the bushing on the brake pedal pin. 14. Install the stoplight switch self-locking pin. 15. Install the instrument panel opening cover. 16. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal > Page 6096 Brake Pedal Assy: Service and Repair Brake Pedal and Bracket Removal 1. CAUTION: The brake pedal and the accelerator pedal must be in the same position when installing a new cable or a new pedal. The pedals must be in the all the way forward or all the way rearward position. Disconnect the battery ground cable. 2. Remove the instrument panel opening cover. 3. Remove the steering column support bracket. 1. Remove the nuts. 2. Remove the steering column support bracket. 4. Remove the stoplight switch self-lock pin. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal > Page 6097 5. Slide the stoplight switch, booster push rod and the bushing off the brake pedal pin. 6. Remove the brake pedal-to-accelerator pedal cable from the accelerator pedal by pulling on the cable retainer. 7. Disconnect the brake pedal motor electrical connector. 8. Remove the bulkhead sound insulator. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal > Page 6098 9. Remove the brake pedal bracket nuts. 10. Remove the brake pedal bracket bolts, and remove the brake pedal and bracket. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal > Page 6099 1. Install the brake pedal bracket bolts. 2. Install the brake pedal bracket and nuts. 3. Install the bulkhead sound insulator. 4. Connect the brake pedal motor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal > Page 6100 5. Install the brake pedal-to-accelerator pedal cable in the accelerator pedal. 6. CAUTION: When installing the brake pedal-to-accelerator pedal cable, the brake pedal and the accelerator pedal must be in the same position, all the way forward or all the way rearward. Position the accelerator pedal using the brake pedal motor, all the way forward or backward, depending on the position of the new brake pedal. 7. Remove the brake pedal-to-accelerator pedal cable from the accelerator pedal by pulling on the cable retainer. 8. Position the brake pedal in the same position as the accelerator pedal, using the brake pedal motor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal > Page 6101 9. Install the brake pedal-to-accelerator pedal cable in the accelerator pedal. 10. When installing a new accelerator pedal, the accelerator pedal will come in the forward or rearward position. Before installing the cable, move the brake pedal with the motor so it is in the same position as the accelerator pedal. 11. Slide the stoplight switch, booster push rod and the bushing on the brake pedal pin. 12. Install the stoplight switch self-locking pin. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal > Page 6102 13. Install the steering column support bracket. 14. Install the instrument panel opening cover. 15. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal > Page 6103 Brake Pedal Assy: Service and Repair Brake Pedal Motor Removal 1. Disconnect the brake pedal motor electrical connector. 2. Remove the brake pedal motor bolts. Installation 1. Note: Hand-tighten bolts. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal > Page 6104 Brake Pedal Assy: Service and Repair Brake Pedal Motor Cable Removal 1. Disconnect the brake pedal motor electrical connector. 2. Remove the brake pedal motor bolts. 3. Remove the brake pedal to motor cable. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Front Brake Caliper: Specifications Caliper bolts 21 - 26 ft.lb Front disc brake caliper anchor plate bolts 126 - 169 ft.lb Rear disc brake caliper hose bolt 9 - 13 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Front > Page 6110 Brake Caliper: Specifications Brake Caliper Bolts 20 ft.lb Caliper Flow Bolt 23 - 29 ft.lb Rear Wheel Disc Brake Adapter Nuts 40 ft.lb Rear disc brake caliper to rear disc brake caliper anchor plate bolts 20 ft.lb Rear disc brake caliper bleeder screw 12 - 18 ft.lb Rear disc brake caliper hose bolt 29 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Caliper Removal and Installation Removal WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Occupational health and safety act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. 1. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and the wheel bearings. Loosen the wheel nuts. 1. Remove the center cap. 2. With the weight of the vehicle on the wheels, loosen the wheel nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 4. CAUTION: Install a new lining if worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. Inspect the pads for wear or contamination. 5. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Disconnect the front brake hose (2078). 1. Remove the front brake hose bolt. 2. Disconnect the front brake hose. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6113 3. Remove the copper washers. Plug the front brake hose. 6. Remove the disc brake caliper. 1. Remove the two caliper bolts using a T45 Torx(R). 2. Lift the disc brake caliper off the front disc brake caliper anchor plate. 7. On 4x2 vehicles, measure the brake disc thickness. ^ Install a new brake disc and hub if not within specification. 8. On 4x4 vehicles, measure the brake disc thickness. ^ Install anew brake disc if not within specification. 9. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6114 1. Install the disc brake caliper. 1. Install the disc brake caliper. 2. Install the front disc brake caliper bolts. 2. Install the front brake hose. ^ Use new copper washers to connect the front brake hose. ^ Install the front brake hose bolt. 3. Bleed the front disc brake caliper. 4. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting surface. 5. Install the tire and wheel assembly. 6. Install the center cap. 7. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Check the brake operation. Caliper Disassembly and Assembly Disassembly 1. Remove the disc brake caliper. 2. Drain the remaining brake fluid from the disc brake caliper. 3. Secure the disc brake caliper in a vise. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6115 4. Remove the caliper pistons. 1. Place a block of wood between the caliper bridge and the caliper pistons. 2. Apply low air pressure to the fluid port in the disc brake caliper. 3. Force out the caliper pistons to the block of wood. 4. Remove the block of wood and the caliper pistons. 5. Remove and discard the piston seals and boots. 6. Note: Do not hone the cylinder bores. Pistons are not available for honed cylinder bores. If the cylinder bores are excessively scored or corroded, replace the disc brake caliper. Assembly CAUTION: Never reuse piston seals and dust boots. Note: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6116 1. Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Install the caliper pistons. 1. Install the piston seal. 2. Install the piston boot on the caliper piston. 3. CAUTION: Be careful not to damage or dislodge the piston seal. Insert the caliper piston. 4. CAUTION: Be careful not to cock the caliper piston. Press the caliper piston in to the cylinder bore. 3. Install the disc brake caliper. Brake Caliper Anchor Plate Removal 1. Remove the pads. 2. Remove the front disc brake caliper anchor plate. 1. Remove the two front disc brake caliper anchor plate bolts. 2. Remove the front disc brake caliper anchor plate. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6117 1. Install the front disc brake caliper anchor plate. 1. Position the front disc brake caliper anchor plate. 2. Install the front disc brake caliper anchor plate bolts. 2. Install the pads. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6118 Brake Caliper: Service and Repair Rear Caliper Removal and Installation Removal WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers, such as a brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. WARNING: If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. WARNING: Occupational safety and health act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. CAUTION: Install new brake pads in complete axle sets. Inspect the brake pads for wear or contamination. ^ Install new brake pads if worn to or past specification. 4. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Disconnect the brake hose. 1. Remove the bolt. 2. Disconnect the rear wheel brake hose. 3. Remove the copper washers, and plug the brake hose. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6119 5. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. At the time of publication there are no approved materials or procedures for relubricating the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism. Remove the rear disc brake caliper. 1. Remove the brake caliper bolts. 2. Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. 6. Inspect the rear disc brake caliper for leaks. ^ If leaks are found, disassembly is required. 7. Measure the brake disc thickness. ^ Install a new brake disc if not within specification. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6120 1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt. Note: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if worn or damaged. Note: When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper. Install the rear disc brake caliper. 2. Install the rear wheel brake hose. ^ Use new copper washers; connect the brake hose and install the caliper flow bolt. 3. Bleed the rear disc brake caliper. 4. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel, wheel hub, or brake disc. Any foreign material on the wheel mounting surfaces can cause the wheel nuts to loosen and come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting surface. 5. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 6. Verify correct brake operation. Caliper Disassembly and Assembly Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6121 Special Tools Disassembly 1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake caliper. 3. Secure the rear disc brake caliper in a vise. 4. Remove the caliper piston. 1. Place a block of wood between the caliper bridge and the caliper piston. 2. Apply low air pressure to the fluid port in the rear disc brake caliper. 3. Force out the caliper piston to the block of wood. 4. Remove the block of wood and the caliper piston. 5. Note: Do not hone the cylinder bore. Caliper pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore is excessively scored or corroded, replace the rear disc brake caliper. Remove and discard the piston seal and dust boot. Assembly CAUTION: Never reuse the piston seal or dust boot. Note: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6122 1. Lubricate the following with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. ^ Cylinder bore. ^ Piston seal. ^ Caliper piston. ^ Dust boot. 2. Install the piston seal. 3. Install the dust boot. 4. CAUTION: Be careful not to damage or dislodge the piston seal. Install the caliper piston. 5. Install the rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 6123 Rear Disc Brake Adapter Removal 1. Disconnect the parking brake rear cable and conduit. 2. Remove the axle shaft. 3. Remove the parking brake shoe and linings. 4. Remove the nuts and the rear wheel disc brake adapter. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Page 6124 Special Tools Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Minimum thickness above backing plate or rivets 0.039 in Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front Removal WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Occupational health and safety act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. 1. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and the wheel bearings. Loosen the wheel nuts. 1. Remove the center cap. 2. With the weight of the vehicle on the wheels, loosen the wheel nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 1. Remove the wheel nuts. 2. Remove the wheel and tire assembly. 4. CAUTION: Install a new lining if worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6130 axle sets. Inspect the pads for wear or contamination. 5. CAUTION: When removing the front disc brake caliper, never allow it to hang from a brake hose. Provide a suitable support. Remove the disc brake caliper. 1. Remove the caliper bolts using a T45 Torx(R). 2. Lift the disc brake caliper off the front disc brake caliper anchor plate. 6. On 4x2 vehicles, measure the brake disc thickness. ^ Install a new brake disc and hub if not within specification. 7. On 4x4 vehicles, measure the brake disc thickness. ^ Install anew brake disc if not within specification. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6131 8. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. 9. Remove the disc brake anti-rattle clips. 1. Remove the pads. 2. Remove the disc brake anti-rattle clips. Installation 1. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the front brake pad lining material. Do not install contaminated pads. Install the pads. 1. Install the disc brake anti-rattle clips. 2. Install the pads. 2. CAUTION: Use care not to damage the bleeder screw or front wheel disc brake shield. Install the disc brake caliper. 1. Install the disc brake caliper. 2. Install the disc brake caliper bolls. 3. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6132 Clean the wheel hub mounting surface. 4. Install the tire and wheel assembly. 5. Install the center cap. 6. Inspect the brake operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6133 Brake Pad: Service and Repair Rear Removal 1. Note: It is not necessary to remove the hydraulic brake line when performing this procedure. Remove the rear disc brake caliper. 2. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the brake pads. Remove the brake pads. 3. Retract the caliper piston into the rear disc brake caliper. 4. Remove the slippers. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 6134 1. Install the slippers. 2. CAUTION: New brake pads should be installed in full axle sets only. Do not install new brake pads on only one side of the vehicle. Install the brake pads. 3. Install the rear disc brake caliper. 4. Verify correct brake operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brake Rotor - Incorrect Discard Thickness Specification Brake Rotor/Disc: Technical Service Bulletins Brake Rotor - Incorrect Discard Thickness Specification Article No. 99-25-6 12/13/99 ^ BRAKES - INCORRECT ROTOR THICKNESS STAMPED ON ROTOR - F-150 4X2 ONLY ^ BRAKES - INCORRECT WORKSHOP MANUAL ROTOR DISCARD THICKNESS SPECIFICATION FORD: 1997-2000 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-2000 NAVIGATOR ISSUE The 1997-2000 Workshop Manuals do not provide the correct and complete specification for rotor discard thickness. Additionally, some 4X2 F-150 rotors may have an incorrect rotor discard thickness stamped on them. Updated Information Per TSB 99-25-6 ACTION Refer to the Front and Rear Disc Rotor Discard Specification Charts for correct rotor discard specification. * SOME 4X2 F-150 ROTORS SHOW "24.7 mm" PRINTED ON THE ROTOR BACK SIDE. THIS IS AN ERROR, THESE CAN BE CUT TO 24.5 mm DISCARD THICKNESS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 390000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc Brake Rotor/Disc: Specifications Brake Rotor/Disc .............................................................................................................................................................. ........................................................ Min Thickness Front .................................................................................................................................................... ............................................. 1.0906 inch (27.70mm) Rear ..................................................................................................................................................... .................................................. 0.4724 inch (12mm) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc > Page 6141 Brake Rotor/Disc: Specifications Brake disc shield screws 89 - 123 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor/Disc: Service and Repair Front Brake Disc Removal 1. Remove the front disc brake caliper anchor plate. 2. On 4x4 vehicles, remove the brake disc. ^ If necessary, resurface the brake disc. Ford recommends on-vehicle rotor machining. Follow the lathe manufacturer's instructions. 3. On 4x2 vehicles, remove the brake disc and hub as follows: 1. Remove the hub grease cap. 2. Remove the cotter pin. 3. Remove the nut retainer. 4. Remove the spindle nut. 5. Remove the front wheel outer bearing retainer washer. 6. Remove the outer front wheel bearing. 7. Remove the brake disc and hub. 4. If necessary on 4x2 vehicles, resurface the brake disc and hub. Ford recommends on-vehicle brake disc machining. Follow the lathe manufacturer's instructions. 1. Remove the wheel hub grease seal. 2. Remove the inner front wheel bearing. Installation 4. On 4x4 vehicles, position the brake disc. 1. Use Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent. ^ Clean the brake disc. 2. Position the brake disc. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6144 2. On 4x2 vehicles, use Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent to thoroughly clean and inspect the front wheel bearings and the brake disc and hub. 3. On 4x2 vehicles, lubricate the front wheel bearings. Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M-1C198-A. 4. On 4x2 vehicles, install a new wheel hub grease seal. 1. Install the inner front wheel bearing. 2. Install a new wheel hub grease seal. 5. On 4x2 vehicles, install the brake disc and hub. 1. Position the brake disc and hub. 2. Install the outer front wheel bearing. 3. Install the front wheel outer bearing retainer washer. 4. Install the spindle nut. 6. Note: On 4x2 vehicles, rotate the brake disc and hub while adjusting front wheel bearing end play. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6145 Tighten the spindle nut. 7. Loosen the spindle nut two turns. 8. Tighten the spindle nut while rotating the brake disc counterclockwise. 9. Loosen the spindle nut. 10. Tighten the spindle nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6146 11. On4x2 vehicles, install the following components: 1. nut retainer 2. cotter pin 3. hub grease cap 12. Install the front disc brake caliper anchor plate. Brake Disc Shield Removal 1. Remove the brake disc. 2. On 4x4 vehicles, remove the wheel hub. 3. On 4x2 vehicles, remove the brake disc shield 1. Remove the brake disc shield screws. 2. Remove the brake disc shield. 4. On 4x4 vehicles, remove the brake disc shield 1. Remove the screws. 2. Remove the brake disc shield. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6147 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6148 Brake Rotor/Disc: Service and Repair Rear Brake Disc Removal 1. Note: When removing the rear disc brake caliper in this procedure, it is not necessary to disconnect the rear wheel brake hose. Remove the rear disc brake caliper. 2. Note: If the brake disc binds on the parking brake shoe and lining, remove the adjustment hole access plug and contract the parking brake shoe and lining. Remove the brake disc. 1. Remove the press-on keeper nuts, if so equipped. 2. Remove the brake disc. 3. Inspect the brake disc. ^ Install a new brake disc if not within specification. Installation 1. Install the brake disc. 2. Install the rear disc brake caliper. Brake Disc Shield Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6149 Removal 1. Remove the rear wheel disc brake adapter. 2. Remove the rear wheel disc brake shield. 1. Drill out the rivets. 2. Remove the rear wheel disc brake shield. Installation 1. Note: Because the rear wheel disc brake shield is held in position by the four rear wheel disc brake adapter bolts, new rivets are not required. Seal the rivet holes with Silicone Rubber D6AZ-1 9562-AA or equivalent meeting Ford specification ESB-M4G92-A, and install the rear wheel disc brake shield. 2. Install the rear wheel disc brake adapter. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 6150 Brake Rotor/Disc: Service and Repair Brake Disc Machining Brake Disc Machining WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: Do not install brake discs that are less than the minimum thickness specified. Do not machine a brake disc below the minimum thickness specification. 1. Check wheel bearing end-play and correct as necessary. 2. Remove the tire and wheel. NOTE: Begin at the front of the vehicle unless the vibration has been isolated to the rear. 3. Remove the brake caliper. 4. Inspect the brake linings. Install new brake linings if below specification. For additional information, refer to the appropriate brake section. 5. Measure and record the brake disc thickness. Install a new brake disc if the thickness after machining will be at or below specification. The specification is molded into the brake disc. Do not machine a new brake disc. 6. For vehicles with a two-piece hub and brake disc assembly: ^ Match-mark before disassembly. ^ Remove the brake disc. ^ Using a die grinder with a mild abrasive (Scotch Brite(R) type), remove any rust or corrosion from the hub and brake disc mounting surfaces. ^ Align the match-marks and reinstall the brake disc on the hub. 7. Using the special tool, machine the brake discs. Follow the manufacturer's instructions. After machining, make sure the brake disc still meets the thickness specification. CAUTION: Do not use a bench lathe to machine brake discs. NOTE: The depth of cut must be between 0.10 and 0.20 mm (0.004 and 0.008 inch). Lighter cuts will cause heat and wear. Heavier cuts will cause poor brake disc surface finish. 8. Using a dial indicator, verify that the brake disc lateral runout is now within specification. 9. Remove the special tool hub adapter. 10. Remove any remaining metal chips from the machining operation. 11. For vehicles with a two-piece hub and brake disc assembly: ^ Remove the brake disc from the hub. ^ Remove any remaining metal chips from hub and brake disc mounting surfaces and from the ABS sensor. ^ Apply a high temperature anti-seize lubricant to the mounting surfaces. ^ Using the match marks, mount the brake disc on the hub. 12. Install the caliper. 13. Install the tire and wheel assembly. 14. Test the system for normal operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications Front disc brake caliper bleeder screw 9 - 13 ft.lb Front master cylinder brake tube 17 - 20 ft.lb Rear disc brake caliper bleeder screw 12 - 18 ft.lb Rear master cylinder brake tube 11 - 14 ft.lb Wheel cylinder bleeder screw 63 - 80 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed Brake Bleeding: Service and Repair Brake Master Cylinder - Bench Bleed WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with specified brake fluid. ^ Use High Performance DOT 3 Brake Fluid C6AZ-1 9542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir. 3. Slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles. 4. Remove the short brake tubes. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6157 Brake Bleeding: Service and Repair Brake Master Cylinder - In-Vehicle Bleed Special Tools WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Note: When a new brake master cylinder has been installed or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. Disconnect the brake master cylinder outlet tubes. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6158 2. Install short brake tubes with ends submerged in the brake master cylinder reservoir and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes without air bubbles. 4. Remove the short brake tubes and install the brake outlet tubes. 5. Bleed each brake tube at the brake master cylinder as follows: 1. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 2. Loosen the rear most brake tube fittings until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the brake tube fitting. 3. Repeat this operation until clear, bubble-free fluid comes out. 4. Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. 6. While the assistant maintains pressure on the brake pedal, tighten the brake tubes. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6159 Brake Bleeding: Service and Repair Brake System Gravity Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. Note: When a new brake master cylinder has been installed or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. 1. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Bleed the rear disc brake calipers. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. 2. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. ^ Repeat for LH rear disc brake caliper. 3. Tighten the rear disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6160 4. Bleed the front disc brake calipers. 1. Place a box end wrench on the RH front disc brake caliper bleeder screw. 2. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. ^ Repeat for LH front disc brake caliper. 5. Tighten the front disc brake caliper bleeder screws. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6161 Brake Bleeding: Service and Repair Brake System Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. 5. Repeat Steps 1, 2, 3, and 4 for the LH rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6162 6. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 7. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 8. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 9. Tighten the RH front disc brake caliper bleeder screw. 10. Repeat Steps 6, 7, 8, and 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6163 Brake Bleeding: Service and Repair Brake Master Cylinder - Bench Bleed WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Support the brake master cylinder body in a vise and fill the brake master cylinder reservoir with specified brake fluid. ^ Use High Performance DOT 3 Brake Fluid C6AZ-1 9542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir. 3. Slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles. 4. Remove the short brake tubes. Brake Master Cylinder - In-Vehicle Bleed Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6164 Special Tools WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Note: When a new brake master cylinder has been installed or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. Disconnect the brake master cylinder outlet tubes. 2. Install short brake tubes with ends submerged in the brake master cylinder reservoir and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes without air bubbles. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6165 4. Remove the short brake tubes and install the brake outlet tubes. 5. Bleed each brake tube at the brake master cylinder as follows: 1. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 2. Loosen the rear most brake tube fittings until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the brake tube fitting. 3. Repeat this operation until clear, bubble-free fluid comes out. 4. Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. 6. While the assistant maintains pressure on the brake pedal, tighten the brake tubes. Brake System Gravity Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. Note: When a new brake master cylinder has been installed or the system has been emptied, or partially emptied, it should be primed to prevent air from getting into the system. 1. Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Bleed the rear disc brake calipers. 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. 2. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. ^ Repeat for LH rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6166 3. Tighten the rear disc brake caliper bleeder screws. 4. Bleed the front disc brake calipers. 1. Place a box end wrench on the RH front disc brake caliper bleeder screw. 2. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Open the bleeder screw and leave open until clear bubble-free brake fluid flows. ^ Repeat for LH front disc brake caliper. 5. Tighten the front disc brake caliper bleeder screws. Brake System Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6167 1. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. 5. Repeat Steps 1, 2, 3, and 4 for the LH rear disc brake caliper. 6. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 7. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 8. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6168 9. Tighten the RH front disc brake caliper bleeder screw. 10. Repeat Steps 6, 7, 8, and 9 for the LH front disc brake caliper bleeder screw. 11. If necessary, bleed the brake master cylinder. Brake System Pressure Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. Note: Bleed the longest line first. Be sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. Note: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6169 3. Place a box end wrench on the RH rear disc brake caliper bleeder screw. Attach a rubber drain tube to the RH rear disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the rear disc brake caliper bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten rear disc brake caliper bleeder screw and remove the rubber hose. 6. Continue bleeding the rest of the system, going in order from the LH rear disc brake caliper to the RH front disc brake caliper (213121) ending with the LH front disc brake caliper. 7. Close the bleeder tank valve and remove the tank hose from the adapter and remove the adapter. 8. Fill the brake master cylinder reservoir and install the brake master cylinder filler cap. Four Wheel Antilock Brake System Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Note: When any part of the hydraulic system has been disconnected for repair or new installation, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. Note: This procedure must be performed if the 4 wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been installed new. Note: One conventional pressure bleed cycle consists of advancing the brake pedal to its depressed position, opening the disc brake caliper bleeder screw, allowing fluid to be released into the waste container, closing the disc brake caliper bleeder screw and releasing the brake pedal. Note: Performing the NGS program routine drives entrapped air from the otherwise inaccessible lower section of the 4WABS valve into the upper sections (accessible by bleeding the brakes). Subsequent bleedings remove the air from the system. Note: Add recommended brake fluid as necessary throughout the procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6170 1. Connect a clear waste line to the RH rear disc brake caliper bleeder screw and the other end in a container partially filled with recommended brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the RH rear disc brake caliper bleeder screw until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal while tightening the RH rear disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear disc brake caliper bleeder screw. 5. Repeat Steps 1, 2, 3, and 4 for the LH rear disc brake caliper bleeder screw, RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw. 6. Note: Go to the help menu in the scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Brake Master Cylinder - Bench Bleed > Page 6171 Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the dash and follow the scan tool instructions. 7. Repeat the conventional bleed procedure as outlined in Steps 1 through 5. 8. If the brake pedal feels spongy, repeat the scan tool service bleed procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Page 6172 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Front Brake Caliper: Specifications Caliper bolts 21 - 26 ft.lb Front disc brake caliper anchor plate bolts 126 - 169 ft.lb Rear disc brake caliper hose bolt 9 - 13 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Front > Page 6177 Brake Caliper: Specifications Brake Caliper Bolts 20 ft.lb Caliper Flow Bolt 23 - 29 ft.lb Rear Wheel Disc Brake Adapter Nuts 40 ft.lb Rear disc brake caliper to rear disc brake caliper anchor plate bolts 20 ft.lb Rear disc brake caliper bleeder screw 12 - 18 ft.lb Rear disc brake caliper hose bolt 29 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Caliper Removal and Installation Removal WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Occupational health and safety act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. 1. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and the wheel bearings. Loosen the wheel nuts. 1. Remove the center cap. 2. With the weight of the vehicle on the wheels, loosen the wheel nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 4. CAUTION: Install a new lining if worn to or past the specified thickness above the metal backing plate or rivets. Install new pads in complete axle sets. Inspect the pads for wear or contamination. 5. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Disconnect the front brake hose (2078). 1. Remove the front brake hose bolt. 2. Disconnect the front brake hose. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6180 3. Remove the copper washers. Plug the front brake hose. 6. Remove the disc brake caliper. 1. Remove the two caliper bolts using a T45 Torx(R). 2. Lift the disc brake caliper off the front disc brake caliper anchor plate. 7. On 4x2 vehicles, measure the brake disc thickness. ^ Install a new brake disc and hub if not within specification. 8. On 4x4 vehicles, measure the brake disc thickness. ^ Install anew brake disc if not within specification. 9. Inspect the disc brake caliper for leaks. ^ If leaks are found, disassembly is required. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6181 1. Install the disc brake caliper. 1. Install the disc brake caliper. 2. Install the front disc brake caliper bolts. 2. Install the front brake hose. ^ Use new copper washers to connect the front brake hose. ^ Install the front brake hose bolt. 3. Bleed the front disc brake caliper. 4. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting surface. 5. Install the tire and wheel assembly. 6. Install the center cap. 7. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Check the brake operation. Caliper Disassembly and Assembly Disassembly 1. Remove the disc brake caliper. 2. Drain the remaining brake fluid from the disc brake caliper. 3. Secure the disc brake caliper in a vise. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6182 4. Remove the caliper pistons. 1. Place a block of wood between the caliper bridge and the caliper pistons. 2. Apply low air pressure to the fluid port in the disc brake caliper. 3. Force out the caliper pistons to the block of wood. 4. Remove the block of wood and the caliper pistons. 5. Remove and discard the piston seals and boots. 6. Note: Do not hone the cylinder bores. Pistons are not available for honed cylinder bores. If the cylinder bores are excessively scored or corroded, replace the disc brake caliper. Assembly CAUTION: Never reuse piston seals and dust boots. Note: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6183 1. Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Install the caliper pistons. 1. Install the piston seal. 2. Install the piston boot on the caliper piston. 3. CAUTION: Be careful not to damage or dislodge the piston seal. Insert the caliper piston. 4. CAUTION: Be careful not to cock the caliper piston. Press the caliper piston in to the cylinder bore. 3. Install the disc brake caliper. Brake Caliper Anchor Plate Removal 1. Remove the pads. 2. Remove the front disc brake caliper anchor plate. 1. Remove the two front disc brake caliper anchor plate bolts. 2. Remove the front disc brake caliper anchor plate. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6184 1. Install the front disc brake caliper anchor plate. 1. Position the front disc brake caliper anchor plate. 2. Install the front disc brake caliper anchor plate bolts. 2. Install the pads. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6185 Brake Caliper: Service and Repair Rear Caliper Removal and Installation Removal WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers, such as a brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. WARNING: If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. WARNING: Occupational safety and health act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. CAUTION: Install new brake pads in complete axle sets. Inspect the brake pads for wear or contamination. ^ Install new brake pads if worn to or past specification. 4. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Disconnect the brake hose. 1. Remove the bolt. 2. Disconnect the rear wheel brake hose. 3. Remove the copper washers, and plug the brake hose. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6186 5. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. At the time of publication there are no approved materials or procedures for relubricating the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism. Remove the rear disc brake caliper. 1. Remove the brake caliper bolts. 2. Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. 6. Inspect the rear disc brake caliper for leaks. ^ If leaks are found, disassembly is required. 7. Measure the brake disc thickness. ^ Install a new brake disc if not within specification. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6187 1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt. Note: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if worn or damaged. Note: When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper. Install the rear disc brake caliper. 2. Install the rear wheel brake hose. ^ Use new copper washers; connect the brake hose and install the caliper flow bolt. 3. Bleed the rear disc brake caliper. 4. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel, wheel hub, or brake disc. Any foreign material on the wheel mounting surfaces can cause the wheel nuts to loosen and come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting surface. 5. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 6. Verify correct brake operation. Caliper Disassembly and Assembly Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6188 Special Tools Disassembly 1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake caliper. 3. Secure the rear disc brake caliper in a vise. 4. Remove the caliper piston. 1. Place a block of wood between the caliper bridge and the caliper piston. 2. Apply low air pressure to the fluid port in the rear disc brake caliper. 3. Force out the caliper piston to the block of wood. 4. Remove the block of wood and the caliper piston. 5. Note: Do not hone the cylinder bore. Caliper pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore is excessively scored or corroded, replace the rear disc brake caliper. Remove and discard the piston seal and dust boot. Assembly CAUTION: Never reuse the piston seal or dust boot. Note: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6189 1. Lubricate the following with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. ^ Cylinder bore. ^ Piston seal. ^ Caliper piston. ^ Dust boot. 2. Install the piston seal. 3. Install the dust boot. 4. CAUTION: Be careful not to damage or dislodge the piston seal. Install the caliper piston. 5. Install the rear disc brake caliper. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6190 Rear Disc Brake Adapter Removal 1. Disconnect the parking brake rear cable and conduit. 2. Remove the axle shaft. 3. Remove the parking brake shoe and linings. 4. Remove the nuts and the rear wheel disc brake adapter. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Page 6191 Special Tools Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Brake Fluid High Performance DOT 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Specifications Brake Fluid Level Sensor/Switch: Specifications Brake pressure switch ......................................................................................................................... ........................................... 14-20 Nm (11-14 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Specifications > Page 6198 Brake Fluid Level Sensor/Switch: Description and Operation The brake fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid from either the primary (front) or secondary (rear) system will cause this system to activate. If the brake fluid level warning switch is inoperative, a new brake master cylinder reservoir must be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Front brake hose bolt 20 - 26 ft.lb Front brake hose bracket 10 - 12 ft.lb Front brake hose plug 10 - 12 ft.lb Front brake hose bolt 23-29 ft.lb Left rear brake hose bracket bolt 10 - 12 ft.lb 1/2-20 Hydraulic brake tube 17 ft.lb 7/16-24 Hydraulic brake tube 13 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 6202 Brake Hose/Line: Description and Operation CAUTION: Only Ford authorized inlet hydraulic brake tubes should be used. These tubes are of a specific design and new Ford authorized parts only should be installed. Steel tubing with flex hoses are used in the hydraulic lines between the brake master cylinder and the hydraulic control unit. Steel tubing is used between the hydraulic control unit and the front and rear hoses. Double flared brake tubing should provide good leakproof connections. When replacing hydraulic brake tubing, hoses, or connectors, tighten all connections securely. After replacement, bleed the brake system. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Electronic hydraulic control unit (EHCU) bracket bolts to frame 22 ft.lb Electronic hydraulic control unit (EHCU) bolts to bracket 26 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6206 Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection For further information regarding this component and the system that it is a part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6207 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal and Installation 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery negative cable. 2. Disconnect the anti-lock brake control module electrical connector. 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, Hush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Only Ford authorized inlet hydraulic brake tubes should be used. These tubes are of specific design and only Ford authorized parts should be used when installing new inlet brake tubes. Note: Plug each open port to prevent brake fluid from spilling. Disconnect the hydraulic brake tubes. 4. Remove the bolts and the hydraulic control unit (HCU). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 6208 5. If necessary, remove the bolts and the HCU bracket. 6. To install, reverse the removal procedure. 7. Bleed the brake system. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Brake Master Cylinder Brake Master Cylinder: Specifications Brake master cylinder spacer 22 - 36 ft.lb Brake master cylinder nuts 17 - 20 ft.lb Front master cylinder brake line 17 - 20 ft.lb Rear master cylinder brake line 11 - 14 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Brake Master Cylinder > Page 6213 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 6214 Brake Master Cylinder: Description and Operation The brake master cylinder is a dual-piston type. The brake master cylinder is assisted by a power brake booster. The following conditions are considered normal, and are not indications that the brake master cylinder is in need of repair or replacement: ^ Low brake fluid level detected without signs of leakage. This condition is caused by displacement of brake fluid from the brake master cylinder reservoir into the disc brake calipers to compensate for normal brake wear. Add brake fluid as needed. ^ A momentary or slight ripple of brake fluid inside the brake master cylinder reservoir upon application or release of the brake pedal. ^ A trace of brake fluid found on the outside of the power brake booster below the brake master cylinder mounting flange. This condition results from the lubricating action of the brake master cylinder wiping seal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 6215 Brake Master Cylinder: Testing and Inspection Normal Conditions The following conditions are considered normal and are not indications that the brake master cylinder is in need of service. Condition 1: During normal operation of the brake master cylinder, the fluid level in the brake master cylinder reservoir will rise during brake application and fall during release. The net fluid level (i.e., after brake application and release) will remain unchanged. Condition 2: A trace of brake fluid will exist on the booster shell below the master cylinder mounting flange. This results from the normal lubricating action of the master cylinder bore and seal. Condition 3: Fluid level will decrease with pad wear. Abnormal Conditions Changes in brake pedal feel or travel are indicators that something could be wrong in the brake system. Refer to the symptom chart at Brakes and Traction Control/Testing and Inspection for abnormal condition diagnosis. Bypass Condition Test 1. Disconnect the brake lines at the brake master cylinder. 2. Plug the outlet ports of the brake master cylinder. 3. Apply the brakes. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and must be rebuilt or replaced. Compensator Port Check The purpose of the compensator ports in the brake master cylinder is to supply any additional brake fluid required by the system due to brake pad wear and to allow brake fluid returning from the brake lines to the brake master cylinder to enter the brake master cylinder reservoir. The returning brake fluid will cause a slight turbulence in the brake master cylinder reservoir. Turbulence seen in the brake master cylinder reservoir upon release of the brake pedal is normal and shows that the compensating ports are not plugged. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 6216 Brake Master Cylinder: Adjustments Master Cylinder Push Rod Adjustment 1. Remove the brake master cylinder. 2. Adjust the power brake booster to brake master cylinder push rod length. 1. Measure the power brake booster to brake master cylinder push rod. 2. If necessary, adjust the screw to the correct length. 3. Install the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation Brake Master Cylinder: Service and Repair Removal and Installation Removal WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. 1. Disconnect the battery ground cable. 2. Disconnect the brake fluid level warning switch electrical connector. 3. On speed control equipped vehicles, disconnect the brake pressure switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 6219 4. Note: Use two wrenches on the tube nut at the spacer so as not to loosen the spacer. Disconnect the two brake lines, and plug the lines and the brake master cylinder ports. 5. Remove the brake master cylinder. 1. Remove the two brake master cylinder nuts. 2. Remove the brake master cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Bleed the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 6220 Brake Master Cylinder: Service and Repair Disassembly and Assembly Disassembly WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. 1. Remove the brake master cylinder. 2. Clean the outside of the brake master cylinder. 3. Remove the brake master cylinder filler cap and drain the remaining brake fluid. Do not reuse the drained fluid. 4. On speed control equipped vehicles, remove the brake pressure switch. 5. Remove the brake master cylinder spacer. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 6221 6. Remove the primary piston assembly. 1. Depress the primary piston, and remove the snap ring. 2. Remove and discard the primary piston assembly. 7. Remove the secondary piston assembly. 1. Plug the rear outlet port and, if necessary, plug the brake pressure switch port. 2. Apply compressed air into the front outlet port, and carefully remove the secondary piston assembly and discard. 8. Note: If the brake master cylinder bore is damaged, a new brake master cylinder must be installed. Use isopropyl alcohol to clean and inspect the brake master cylinder bore for damage. Assembly WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. 1. Lubricate the new piston assembly seals. Use clean High-Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Do not use oil as it will destroy the seals. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 6222 2. Carefully install the secondary piston assembly. 3. Carefully install the primary piston assembly. 4. Install the snap ring. 1. Depress the primary piston. 2. Install the snap ring. 5. Install the brake master cylinder spacer. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 6223 6. On speed control equipped vehicles, install the brake pressure switch. 7. Fill the brake master cylinder reservoir with clean High Performance DOT3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A, and install the brake master cylinder filler cap. 8. Bleed the brake master cylinder. 9. Install the brake master cylinder. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 6224 Brake Master Cylinder: Service and Repair Brake Fluid Reservoir Removal WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. 1. Disconnect the battery ground cable. 2. Disconnect the brake master cylinder fluid level warning switch electrical connector. 3. Use a suitable suction device to drain the brake master cylinder reservoir. Do not reuse the drained fluid. 4. Carefully pry upon the brake master cylinder reservoir to remove. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal and Installation > Page 6225 1. Note: Whenever installing a new brake master cylinder reservoir, install new grommets. Install the brake master cylinder reservoir. 1. Lubricate the two grommets with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT3 fluid meeting Ford specification ESA-M6C25-A, and insert the grommets in the brake master cylinder. 2. Press the brake master cylinder reservoir into the grommets until it snaps. 3. Connect the brake master cylinder fluid level warning switch electrical connector. 4. Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 2. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications Parking Brake Cable: Specifications Torque Specifications Parking brake cable and conduit clip bolt .............................................................................................................................. 15-20 Nm (11-14.7 ft. lbs.) Parking brake cable retainer clip screw ....................................................................................................................................... 11-15 Nm (8-11 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front Parking Brake Cable: Service and Repair Cable and Conduit - Front Removal 1. Remove the parking brake control. 2. Disconnect the front parking brake cable and conduit from the RH parking brake rear cable and conduit. 3. Remove the front parking brake cable and conduit. 1. Pry the rubber seal from the front floor pan. 2. Compress the retainer and release the front parking brake cable and conduit from the bracket. 3. Remove the front parking brake cable and conduit. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6232 Parking Brake Cable: Service and Repair Cable and Conduit - LH Rear Removal 1. Note: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1. Pull the front parking brake cable and conduit. 2. Insert a suitable retainer. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Separate the RH parking brake rear cable and conduit from the LH parking brake rear cable and conduit at the parking brake cable equalizer. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6233 4. Remove the LH parking brake rear cable and conduit from the parking brake cable bracket. 1. Compress the parking brake cable clip. 2. Remove the LH parking brake rear cable and conduit from the parking brake cable bracket. 5. Remove the screw. 6. Compress the retainer and release the parking brake rear cable and conduit from the rear disc brake caliper anchor plate. 7. Unclip the parking brake rear cable and conduit from the parking brake ]ever. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6234 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6235 Parking Brake Cable: Service and Repair Cable and Conduit - RH Rear Removal 1. Note: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1. Pull the front parking brake cable and conduit. 2. Insert a suitable retainer. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Disconnect the front parking brake cable and conduit from the R11 parking brake rear cable and conduit. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6236 4. Compress the parking brake cable clip. Remove the RH parking brake rear cable and conduit from the parking brake cable equalizer. 5. Remove the screw. 6. Compress the retainer and release the parking brake rear cable and conduit from the rear disc brake caliper anchor plate. 7. Unclip the parking brake rear cable and conduit from the parking brake lever (2A637). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Cable and Conduit - Front > Page 6237 8. Remove the pushpin located in the crossmember and the RH parking brake rear cable and conduit. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications Parking Brake Control: Specifications Torque Specifications Parking brake control to cowl panel bolts ................................................................................................................................ 15-20 Nm (1-14.7 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6241 Parking Brake Control: Service and Repair Removal 1. Note: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1. Pull the front parking brake cable and conduit. 2. Insert a suitable retainer. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6242 4. Pull to release the three clips and remove the instrument panel steering column cover. 5. Remove the parking brake automatic release motor, if so equipped. 6. Remove the parking brake remote release lever screws. 7. Unhook the remote release lever from the parking brake control. 1. Unhook the cable. 2. Remove the conduit from the clip. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6243 8. Separate the parking brake control from the cowl panel. 1. Remove the bolts. 2. Disconnect the parking brake signal switch connector. 3. Separate the parking brake control from the cowl panel. 9. Disconnect the front parking brake cable and conduit from the parking brake control. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 6244 10. Remove the parking brake control. 1. Compress the connector; release the front parking brake cable and conduit. 2. Remove the front parking brake cable and conduit. 3. Remove the parking brake control. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Motor > Component Information > Service and Repair > Parking Brake Release Motor Parking Brake Release Motor: Service and Repair Parking Brake Release Motor Removal and Installation 1. Disconnect the vacuum hose. 2. Remove the screw. 3. Note: Pull and hold the manual release handle to expose the motor-to-release connection. Remove the motor. 4. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Motor > Component Information > Service and Repair > Parking Brake Release Motor > Page 6249 Parking Brake Release Motor: Service and Repair Parking Brake Release Solenoid Removal and Installation 1. Disconnect the electrical connector. 2. Disconnect the vacuum hoses. 3. Unclip and slide the solenoid off the bracket. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications Parking brake remote release to instrument panel bolts: 2.1-2.9 Nm (18.7-25.8 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Specifications > Page 6253 Parking Brake Release Switch: Service and Repair Removal and Installation 1. Disconnect the battery. 2. Note: Move the shift lever to the 1 position to case removal. Carefully pry to release four clips and remove the steering column opening cover. 3. Pull to release the three clips and remove the instrument panel fuse door. 4. Position the hood latch release handle aside. 1. Remove the screws. 2. Position the hood latch release handle aside. 5. Position the parking brake release handle aside. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Specifications > Page 6254 1. Remove the screws. 2. Position the parking brake release handle aside. 6. Remove the instrument panel steering column cover. 1. Remove the bolts. 2. Remove the instrument panel steering column cover. 7. Remove the nuts and the instrument panel opening cover support. 8. Loosen the rear nuts. Remove the front nuts and lower the steering column. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Specifications > Page 6255 9. Disconnect the electrical connector. 10. Remove the bolts and the transmission shift selector position insert with attached switch. 11. To install, reverse the removal procedure. ^ Make sure the transmission shift selector position insert is correctly installed onto the brake shift interlock solenoid and the shift lever. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair Parking Brake Shoe: Service and Repair Special Service Tool(s) Removal 1. Note: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1. Pull the front parking brake cable and conduit. 2. Insert a suitable retainer. 2. Remove the brake disc. 3. Remove the brake shoe retracting spring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 6259 4. Remove the brake shoe adjusting screw spring. 5. Remove the brake adjuster screw. 6. Remove the brake shoe hold-down spring. 7. Remove the parking brake shoe and linings. 8. Inspect the components for excessive wear or damage and install new components as necessary. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 6260 1. Install the parking brake shoe and linings. 2. Install the brake shoe hold-down spring. 3. Install the brake adjuster screw. 4. Install the brake shoe adjusting screw spring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 6261 5. Install the brake shoe retracting spring. 6. Use the brake adjusting gauge to measure the inside diameter of the drum portion of the brake disc. 7. Use the brake adjusting gauge to set the rear brake shoe and lining diameter. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 6262 8. Install the brake disc. 9. Apply tension to the parking brake system. 1. Hold the front parking brake cable and conduit taut. 2. Remove the retainer. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 6263 Special Tools Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Specifications Parking Brake Warning Switch: Specifications Parking brake signal switch screw ..................................................................................................................................................... 2-3 Nm (18-27 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Power brake booster nuts 16 - 21 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6271 Vacuum Brake Booster: Description and Operation The power brake booster: ^ is a dual diaphragm, vacuum-assisted power brake booster. ^ reduces brake pedal pressure and travel distance. ^ is located on the LH side of the bulkhead in the engine compartment, between the brake pedal and brake master cylinder. ^ is divided into separate chambers by the diaphragm. ^ will not operate if vacuum is restricted or if any of the vacuum-related power brake components fail. ^ is replaced as an assembly. If the power assist fails, the brake system will continue to operate with increased brake pedal effort. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 6272 Vacuum Brake Booster: Testing and Inspection 1. Check the hydraulic brake system for leaks or insufficient fluid. 2. With the transmission (7003) in NEUTRAL, stop the engine (6007) and apply the parking brake control. Apply the brake pedal several times to exhaust all vacuum in the system. 3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system is operating, the brake pedal will tend to move downward under constant foot pressure. If no motion is felt, the power brake booster system is not functioning. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Description and Operation Vacuum Brake Booster Check Valve: Description and Operation The power brake booster check valve: ^ is located on the front of the power brake booster. ^ is positioned between the power brake booster and the power brake booster hose. ^ closes when the engine is turned off. ^ in the closed position, traps engine vacuum in the power brake booster. ^ retains vacuum to provide several power-assisted brake applications with the engine off. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Description and Operation > Page 6276 Vacuum Brake Booster Check Valve: Testing and Inspection The function of the power brake booster check valve is to allow manifold vacuum to enter the power brake booster and prevent the escape of vacuum in case manifold vacuum is lost during sustained full throttle operation. To test the function of the power brake booster check valve : ^ Start and run the engine for at least 10 seconds. ^ Operate the brake pedal to check for power assist. ^ Disconnect the vacuum booster hose from the power brake booster. Do not remove the power brake booster check valve from the power brake booster. ^ There should be enough vacuum retained in the power brake booster for at least one more power-assisted brake operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Description and Operation > Page 6277 Vacuum Brake Booster Check Valve: Service and Repair Removal 1. Remove the brake master cylinder. 2. Disconnect the power brake booster hose. 1. Compress the clamp. 2. Disconnect the power brake booster hose. 3. Remove the stoplight switch self-lock pin (00923-10810). 4. Slide the stoplight switch (13480), booster push rod (2005) and the bushing (2471) off the brake pedal pin. 5. Remove the bulkhead sound insulator. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Description and Operation > Page 6278 6. Remove the power brake booster (2005). 1. Remove the nuts. 2. Remove the power brake booster. Installation 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications Anti-lock brake control module screws 44 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6283 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6284 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6285 Electronic Brake Control Module: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 6286 Electronic Brake Control Module: Service and Repair Removal and Installation 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Disconnect the anti-lock brake control module electrical connector. 3. Disconnect the pump motor electrical connector from the anti-lock brake control module. 4. Remove the screws and the anti-lock brake control module. 5. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Specifications Brake Fluid Level Sensor/Switch: Specifications Brake pressure switch ......................................................................................................................... ........................................... 14-20 Nm (11-14 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Specifications > Page 6291 Brake Fluid Level Sensor/Switch: Description and Operation The brake fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid from either the primary (front) or secondary (rear) system will cause this system to activate. If the brake fluid level warning switch is inoperative, a new brake master cylinder reservoir must be installed. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Differential Speed Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications Parking brake remote release to instrument panel bolts: 2.1-2.9 Nm (18.7-25.8 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Specifications > Page 6298 Parking Brake Release Switch: Service and Repair Removal and Installation 1. Disconnect the battery. 2. Note: Move the shift lever to the 1 position to case removal. Carefully pry to release four clips and remove the steering column opening cover. 3. Pull to release the three clips and remove the instrument panel fuse door. 4. Position the hood latch release handle aside. 1. Remove the screws. 2. Position the hood latch release handle aside. 5. Position the parking brake release handle aside. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Specifications > Page 6299 1. Remove the screws. 2. Position the parking brake release handle aside. 6. Remove the instrument panel steering column cover. 1. Remove the bolts. 2. Remove the instrument panel steering column cover. 7. Remove the nuts and the instrument panel opening cover support. 8. Loosen the rear nuts. Remove the front nuts and lower the steering column. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Specifications > Page 6300 9. Disconnect the electrical connector. 10. Remove the bolts and the transmission shift selector position insert with attached switch. 11. To install, reverse the removal procedure. ^ Make sure the transmission shift selector position insert is correctly installed onto the brake shift interlock solenoid and the shift lever. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Specifications Parking Brake Warning Switch: Specifications Parking brake signal switch screw ..................................................................................................................................................... 2-3 Nm (18-27 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front anti-lock brake sensor bolt 63 - 80 in.lb Rear anti-lock brake sensor bolt 20 ft.lb Anti-lock brake sensor screws 89 - 123 in.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Right Front Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Right Front > Page 6309 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front Wheel Speed Sensor: Service and Repair Sensor, Front Removal 1. Disconnect the front brake anti-lock sensor electrical connector. 2. Remove the front disc brake rotor shield. 3. Remove the (A) front brake anti-lock sensor bolts and the (B) front brake anti-lock sensor. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 6312 Wheel Speed Sensor: Service and Repair Sensor, Rear Removal 1. Raise and support vehicle. 2. Note: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1. Disconnect the rear anti-lock brake sensor electrical connector. 2. Remove the bolt. 3. Remove the rear anti-lock brake sensor. Installation 1. Note: Thoroughly clean the mounting surface. Note: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with SAE-75W-140 High Performance Rear Axle Lubricant FITZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation The Clutch Pedal Position (CPP) switch is controlled by the clutch pedal. Depressing the clutch pedal manually closes the CPP switch and allows engine cranking. The CPP switch will also deactivate the speed control system. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6323 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6324 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6325 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6326 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6327 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > 4R70W Transmission Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > 4R70W Transmission > Page 6333 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Charging System Control Module > Component Information > Description and Operation Charging System Control Module: Description and Operation Generator Load The Generator Load Input (GLI) circuit is used by the PCM to determine generator load on the engine. As generator load increases the PCM will adjust idle speed accordingly. This strategy helps reduce idle surges due to switching high current loads. The GLI signal is sent to the PCM from the voltage regulator/generator. The signal is a variable frequency duty cycle. Normal operating frequency is 40 - 250 Hz. Normal signal DC voltage (referenced to ground) is between 1.5 V (low generator load) and 10.5 V (high generator load). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications Battery Cable: Specifications Battery Ground Cable 7-10 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 6345 Battery Cable: Description and Operation Environmental Protection Vehicles are equipped with a 12 Volt maintenance-free battery. The battery and cable system consists of the following components: ^ battery ^ battery cable assembly ^ battery tray Ford Motor Company strongly recommends that lead-acid batteries be returned to an authorized recycling facility for disposal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 6346 Battery Cable: Service and Repair REMOVAL 1. Disconnect the battery. Refer to Battery Disconnect. 2. Remove the junction block splash shield. 3. Disconnect the cable. 1 Remove the relay nuts. 2 Remove the ground bolt. 4. Remove the bolt. 5. Remove the starter motor solenoid terminal cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications > Page 6347 6. Disconnect the starter motor connections. 1 Remove the starter motor ground cable nut and disconnect the starter motor ground cable. 2 Remove the solenoid cable nut and disconnect the solenoid cable. 3 Remove the starter motor positive cable nut and disconnect the starter motor positive cable. 7. Remove the cables. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Electrical Specifications Generator: Electrical Specifications Generator 110 A Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Electrical Specifications > Page 6353 Generator: Mechanical Specifications Generator B+ Nut And Washer Assembly 8 Nm Front Generator Bolts 25 Nm Generator Bracket Bolts 10 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions Generator: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6356 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6357 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6358 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6359 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6360 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6361 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6362 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6363 Generator: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6364 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6365 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6366 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6367 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6368 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Diagram Information and Instructions > Page 6369 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Page 6370 Generator: Description and Operation The charging system consists of the following components ^ battery ^ generator ^ generator voltage regulator wiring ^ voltage regulator Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Page 6371 Generator: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Starting and Charging; Charging System; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Diagrams > Page 6372 Generator: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the drive belt. For additional information, refer to Drive Belts, Mounts, Brackets and Accessories. 3. Remove the generator bracket bolts. 4. Remove the generator mounting bolts and remove the generator. 5. Disconnect the generator electrical connectors. 1 Disconnect the strator and voltage regulator connectors. 2 Remove the generator B+ nut. 3 Disconnect the generator B+ cable. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Charging System Control Module > Component Information > Description and Operation Charging System Control Module: Description and Operation Generator Load The Generator Load Input (GLI) circuit is used by the PCM to determine generator load on the engine. As generator load increases the PCM will adjust idle speed accordingly. This strategy helps reduce idle surges due to switching high current loads. The GLI signal is sent to the PCM from the voltage regulator/generator. The signal is a variable frequency duty cycle. Normal operating frequency is 40 - 250 Hz. Normal signal DC voltage (referenced to ground) is between 1.5 V (low generator load) and 10.5 V (high generator load). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Service and Repair Voltage Regulator: Service and Repair NOTE: The generator brush and terminal holder and the voltage regulator are installed as an assembly only. 1. Remove the generator, refer to Generator. 2. Remove the generator brush and terminal holder and the voltage regulator assembly. 1 Remove the screws. 2 Remove the generator brush and terminal holder and voltage regulator assembly. INSTALLATION 1. Install the generator brush and terminal holder and the voltage regulator assembly. 1 Depress the brushes and insert a wire to hold brushes during installation. 2 Install the generator brush and terminal holder and the voltage regulator assembly. 3 Install the screws and remove the wire. 2. Remove the generator, refer to Generator. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation The Clutch Pedal Position (CPP) switch is controlled by the clutch pedal. Depressing the clutch pedal manually closes the CPP switch and allows engine cranking. The CPP switch will also deactivate the speed control system. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6388 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6389 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6390 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6391 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 6392 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > 4R70W Transmission Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > 4R70W Transmission > Page 6398 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition Starter Cable: Customer Interest Starting System- No Crank Condition TSB 06-19-14 10/02/06 NO CRANK / STARTER TERMINAL FATIGUE FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006 E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac LINCOLN: 1998-2006 Navigator 2003-2005 Aviator MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit at the starter motor connection. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire harness for the terminal connection. NOTE TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT. Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure. NOTE REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION PROCEDURES. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061914A Install Wiring Pigtail kit (Do 0.4 Hr. Not Use With 14200A) MT061914 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition > Page 6407 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition Starter Cable: All Technical Service Bulletins Starting System- No Crank Condition TSB 06-19-14 10/02/06 NO CRANK / STARTER TERMINAL FATIGUE FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006 E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac LINCOLN: 1998-2006 Navigator 2003-2005 Aviator MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to starter motor circuit at the starter motor connection. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire harness for the terminal connection. NOTE TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT. Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure. NOTE REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION PROCEDURES. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061914A Install Wiring Pigtail kit (Do 0.4 Hr. Not Use With 14200A) MT061914 Claim Additional Labor Actual Required As Actual Time Time Or Use SLTS Operation If Available DEALER CODING Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition > Page 6413 CONDITION BASIC PART NO. CODE 14A280 01 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Description and Operation Starter Drive/Bendix: Description and Operation The starter drive: ^ is operated by the starter solenoid. ^ engages the flywheel to turn the engine. ^ has an internal over-running clutch to disengage the starter motor when the engine starts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Description and Operation > Page 6418 Starter Drive/Bendix: Testing and Inspection STARTER DRIVE AND FLYWHEEL RING GEAR INSPECTION 1. Check the wear patterns on the (A) starter drive and the (B) flywheel ring gear. If the wear pattern is normal, install the starter motor; refer to Starter Motor. 2. If the (A) starter drive gear and the flywheel ring gear are not fully meshing or the gears are (B) milled or damaged, replace the starter motor; refer to Starter Motor. Replace the flywheel ring gear; refer to Engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications Starter Solenoid: Specifications Starter Solenoid Terminal Nuts 7 - 9 Nm Solenoid Cable Nut 5 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 6425 Starter Solenoid: Service Precautions WARNING: ^ WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. FAILURE TO FOLLOW THIS PROCEDURE MAY RESULT IN PERSONAL INJURY. ^ WHEN CARRYING OUT MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 6426 Starter Solenoid: Description and Operation The starter solenoid: ^ is an electromagnet. ^ engages the starter drive to the flywheel. ^ when energized, the contacts close, connecting the battery to the starter motor. This causes the starter motor to turn the starter drive. ^ is kept in the energized condition by a hold-in winding until the starter switch is released. When the ignition switch is turned to the START position, the starter motor solenoid relay switch is energized, connecting the battery to the starter solenoid. The starter solenoid moves the drive lever and pin to engage the starter drive with the flywheel ring gear and connects the battery to the starter motor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 6427 Starter Solenoid: Service and Repair REMOVAL WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. FAILURE TO FOLLOW THIS PROCEDURE MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery ground cable. 2. Remove the insulator. 3. Disconnect the starter motor solenoid relay switch wires and cables. ^ Disconnect the engine control sensor wiring terminal. ^ Remove the starter motor solenoid relay switch terminal nuts. ^ Remove the wiring. 4. Remove the starter motor solenoid relay switch. ^ Remove the bolts. ^ Remove the starter motor solenoid relay switch. INSTALLATION WARNING: WHEN CARRYING OUT MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Specifications > Page 6428 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6434 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6435 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6436 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6437 Electrical Accessory Panel: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6438 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6439 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6440 Lock Relay Block Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6441 Behind right hand side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6442 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6443 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions Electrical Accessory Panel: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6446 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6447 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6448 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6449 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6450 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6451 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6452 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6453 Electrical Accessory Panel: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6454 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6455 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6456 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6457 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6458 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6459 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6468 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6469 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6470 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6471 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6472 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6473 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6474 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6475 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6481 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6482 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6483 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6484 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6485 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6486 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6487 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6488 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box Fuse: Locations Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 6493 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 6494 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 6495 Fuse: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 6496 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 6497 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6500 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6501 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6502 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6503 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6504 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6505 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6506 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6507 Fuse: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6508 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6509 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6510 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6511 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6512 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6513 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box Fuse: Application and ID Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 6516 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 6517 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 6518 Fuse: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 6519 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 6520 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box Fuse Block: Locations Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 6525 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 6526 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 6527 Fuse Block: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 6528 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 6529 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6532 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6533 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6534 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6535 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6536 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6537 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6538 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6539 Fuse Block: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6540 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6541 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6542 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6543 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6544 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6545 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6546 Fuse Block: Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6547 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box Fuse Block: Application and ID Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 6550 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 6551 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 6552 Fuse Block: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 6553 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 6554 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6565 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6566 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6567 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6568 Multiple Junction Connector: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6569 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6570 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6571 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6572 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6573 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6574 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6575 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6576 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6577 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6578 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6579 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6580 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6581 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6582 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6583 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6584 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6585 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6586 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6587 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6588 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6589 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6590 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6591 Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6592 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6593 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6594 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6595 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6596 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6597 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6598 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6599 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6600 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6601 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6602 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6603 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6604 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6605 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6606 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6610 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay Power Distribution Relay: Testing and Inspection Trailer Tow Running Lamp Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 6613 Power Distribution Relay: Testing and Inspection Trailer Tow Reversing Lamp Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 6614 Power Distribution Relay: Testing and Inspection Trailer Tow Battery Charge Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6625 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay Power Distribution Relay: Testing and Inspection Trailer Tow Running Lamp Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 6628 Power Distribution Relay: Testing and Inspection Trailer Tow Reversing Lamp Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 6629 Power Distribution Relay: Testing and Inspection Trailer Tow Battery Charge Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box Relay Box: Locations Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6634 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6635 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6636 Relay Box: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6637 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6638 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6641 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6642 Relay Box: Diagrams Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6643 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6644 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6645 Relay Box: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6646 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6647 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6648 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box Relay Box: Application and ID Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6651 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6652 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6653 Relay Box: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6654 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6655 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box Relay Box: Locations Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6660 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6661 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6662 Relay Box: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6663 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6664 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6667 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6668 Relay Box: Diagrams Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6669 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6670 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6671 Relay Box: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6672 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6673 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6674 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box Relay Box: Application and ID Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6677 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6678 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6679 Relay Box: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6680 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6681 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6686 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6687 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6688 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6689 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6690 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6691 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6692 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6693 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6694 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6700 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6701 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6702 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6703 Electrical Accessory Panel: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6704 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6705 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6706 Lock Relay Block Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6707 Behind right hand side of instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6708 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Battery Junction Box > Page 6709 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions Electrical Accessory Panel: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6712 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6713 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6714 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6715 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6716 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6717 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6718 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6719 Electrical Accessory Panel: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6720 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6721 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6722 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6723 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6734 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6735 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6736 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6737 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6738 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6739 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6740 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 6741 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6747 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6748 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6749 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6750 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6751 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6752 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6753 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 6754 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box Fuse: Locations Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 6759 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 6760 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 6761 Fuse: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 6762 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 6763 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6766 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6767 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6768 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6769 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6770 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6771 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6772 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6773 Fuse: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6774 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6775 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6776 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6777 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6778 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 6779 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box Fuse: Application and ID Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 6782 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 6783 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 6784 Fuse: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 6785 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 6786 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box Fuse Block: Locations Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 6791 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 6792 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 6793 Fuse Block: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 6794 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box > Page 6795 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6798 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6799 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6800 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6801 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6802 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6803 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6804 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6805 Fuse Block: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6806 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6807 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6808 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6809 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6810 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6811 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6812 Fuse Block: Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6813 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box Fuse Block: Application and ID Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 6816 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 6817 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 6818 Fuse Block: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 6819 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Battery Junction Box > Page 6820 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6831 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6832 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6833 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6834 Multiple Junction Connector: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6835 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6836 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6837 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6838 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6839 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6840 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6841 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6842 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6843 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6844 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6845 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6846 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6847 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6848 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6849 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6850 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6851 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6852 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6853 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6854 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6855 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6856 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6857 Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6858 Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6859 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6860 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6861 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6862 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6863 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6864 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6865 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6866 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6867 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6868 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6869 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6870 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6871 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 6872 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6876 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay Power Distribution Relay: Testing and Inspection Trailer Tow Running Lamp Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 6879 Power Distribution Relay: Testing and Inspection Trailer Tow Reversing Lamp Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 6880 Power Distribution Relay: Testing and Inspection Trailer Tow Battery Charge Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 6891 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay Power Distribution Relay: Testing and Inspection Trailer Tow Running Lamp Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 6894 Power Distribution Relay: Testing and Inspection Trailer Tow Reversing Lamp Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Trailer Tow Running Lamp Relay > Page 6895 Power Distribution Relay: Testing and Inspection Trailer Tow Battery Charge Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box Relay Box: Locations Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6900 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6901 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6902 Relay Box: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6903 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6904 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6907 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6908 Relay Box: Diagrams Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6909 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6910 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6911 Relay Box: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6912 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6913 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6914 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box Relay Box: Application and ID Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6917 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6918 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6919 Relay Box: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6920 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6921 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box Relay Box: Locations Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6926 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6927 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6928 Relay Box: Locations Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6929 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box > Page 6930 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6933 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6934 Relay Box: Diagrams Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6935 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6936 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6937 Relay Box: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6938 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6939 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Regular Production Option Relay Block #2 > Page 6940 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box Relay Box: Application and ID Battery Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6943 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6944 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6945 Relay Box: Application and ID Central Junction Box Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6946 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box > Page 6947 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6952 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6953 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6954 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6955 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6956 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6957 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6958 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6959 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 6960 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications Alignment: Specifications Alignment Specifications General Alignment Specifications General Alignment Specifications General Alignment Specifications General Alignment Specifications Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 6966 Alignment: Specifications Ride Height Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 6967 Alignment: Specifications Torque Specifications Front Suspension Upper Arm Nuts .......................................................................................................................................... 113-153 Nm (84-112 ft. lbs.) Toe Set Jam Nuts ................................................................................................ ......................................................................... 77-104 Nm (57-77 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6968 Alignment: Description and Operation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6969 Caster and camber are adjusted by means of eccentric cams on the upper control arm mounting bolts. Toe is adjusted by the use of the front wheel spindle tie rod adjusting sleeve. The three basic alignment angles are camber, caster, and toe. Camber and toe affect tire wear and directional stability, caster affects directional stability only. Camber, caster and toe settings change when the vehicle is loaded. The specifications given are static settings with the vehicle unloaded. Camber is the inward or outward tilting of the wheels at the top. When the wheels tilt out at the top the camber is positive (+). When the wheels tilt in at the top the camber is negative (-). The amount of camber is measured in degrees from vertical. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6970 Steering axis inclination (included angle) is the center line drawn through the ball joints when viewed from the front. Caster is the tilting of the steering axis either forward or backward from vertical. A backward tilt is positive (+) and a forward tilt is negative Wheel Track Toe is a measurement of how much the front of the wheels are turned in or out from the straight-ahead position. When the wheels are turned in, toe is positive (+)(toe in). When the wheels are turned out, toe is negative (-)(toe out). Toe is measured in degrees, from side to side and totaled. Toe should only be checked and adjusted after the camber and caster have been set to the proper specifications. Dogtracking Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6971 By design the vehicle has a front track that is wider at the front than the rear. Front track is the distance between the two front tires; rear track is the distance between the two rear tires. Dogtracking is the condition where the rear axle is not square to the chassis. Heavily crowned roads may give the illusion of dogtracking. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment Alignment: Service and Repair Camber and Caster Adjustment 1. Loosen the upper suspension arm nuts to a point where the joints are snug. 2. Note: A pry bar can be used between the front suspension upper arm and the frame pocket to aid in moving the arm. To increase caster and camber, use the following steps. 1. To increase caster, move the front of the front suspension upper arm outboard and move the rear of the front suspension upper arm inboard. 2. To increase camber, move the front suspension upper arm outboard equally. 3. To decrease caster and camber, use the following steps. 1. To decrease caster, move the front of the front suspension upper arm inboard and move the rear of the front suspension upper arm outboard. 2. To decrease camber, move the front suspension on upper arm inboard equally. 4. Note: Each increment of the notches on the frame pocket represents 0.3 degree. Set the caster and camber to specifications. If a caster increase of 0.9 degree is required, move the front of the front suspension upper arm outboard by 3 notches and move the rear of the front suspension upper arm inboard by 3 notches. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 6974 5. Tighten the upper suspension arm nuts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 6975 Alignment: Service and Repair Ride Height RIDE HEIGHT Adjustment Note: For Four Wheel Air Suspension (4WAS) equipped vehicles, the front air shocks need to be vented before measuring or adjusting ride height. 1. Vent the front air shocks. - Using the scan tool, select AIR SUSPENSION CONTROL MODE under the ACTIVE COMMAND MODES menu. Select VENT FRNT command to deflate the front air shocks down. Hold for 30 seconds to allow complete system venting. Do not disconnect the scan tool. Keep it at the same mode as specified to keep the system at diagnostic mode at time of ride height measurement. If the scan tool is disconnected, the system will go to the operational mode and based on signal inputs, will level the vehicle to specified height (trim or kneel). 2. Raise and support the vehicle. - Use a hoist with frictionless plates to support the front wheels. - Normalize the vehicle static ride height. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 6976 3. Measure the front suspension from the center line on the nut side of the front bolt on the front suspension lower arm to the ground, and record. 4. Measure the front suspension from the bottom of the front wheel knuckle to the ground, and record. Note: The ride height specification for base vehicles with new suspension components is higher than the specification for vehicles using original suspension components to allow for new component settling. 5. To obtain the front suspension ride height, subtract the measurement in Step 3 from the measurement in Step 2. - If the measurement is out of specification, ride height adjustment is required. 6. Note: For the front ride height setting procedure on vehicles equipped with Four-Wheel Air Suspension (4WAS) system, refer to Electronic Level Control. See: Suspension/Suspension Control ( Automatic - Electronic ) Note: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 6977 - Use only hand tools for this adjustment. - The ride height measurement on the opposite side from the adjustment may change. Adjust the ride height by tightening or loosening the torsion bar adjusting bolt. Inspect the ride height on both sides after each adjustment. 7. Note: Do not under any circumstances "save rear" ride heights - there are precalibrated values already stored in the control module. Once the mechanical ride heights are set, using the scan tool, select SAVE CALIBRATION VALUES under ACTIVE COMMAND MODE menu to calibrate the module. Trigger through warning message and save FRONT (turn from OFF to ON). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 6978 Alignment: Service and Repair Toe Adjustment 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the "straightforward" position by attaching a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings; follow the equipment manufacturer's instructions. 4. Hold the tie-rod end while loosening the toe set jam nuts. 5. Rotate the front wheel spindle tie-rod adjusting sleeve to desired position. 6. Note: Whenever the toe set jam nuts are loosened for toe adjustment, the nut and tie-rod threads must be cleaned and lubricated. Tighten the jam nuts as follows: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment > Page 6979 1. Make sure the inner and outer ball joint sockets are perpendicular to the ball studs. 2. Hold the adjuster sleeve in position with locking pliers positioned against the lower control arm. 3. Tighten one adjuster sleeve jam nut to the specified torque. 4. Make an alignment mark across the adjuster sleeve and the tightened jam nut. Make a second mark across the jam nut and the tie-rod end threads. 5. Tighten the remaining jam nut. 6. Check the alignment marks. If either mark is out of alignment, check the toe setting. Readjust, if necessary, and repeat these steps. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Air Suspension/Electronic Variable Orifice Steering Module Steering Control Module: Diagrams Air Suspension/Electronic Variable Orifice Steering Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Air Suspension/Electronic Variable Orifice Steering Module > Page 6987 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7000 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7001 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7007 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7008 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Page 7009 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Rear Only System Suspension Control Module: Service and Repair Rear Only System Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Remove the instrument panel cluster panel. 3. Remove the air suspension control module screws. 4. Remove the air suspension control module and bracket assembly. 1. Disconnect the electrical connectors. 2. Remove the air suspension control module and bracket assembly. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Note: The air suspension control module is calibrated with information from the ride height sensor. A new or exchanged air suspension control module requires that the ride height adjustment calibration process be performed; refer to Front Ride Height Resetting - Clear B2140 DTC. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Rear Only System > Page 7012 Suspension Control Module: Service and Repair 4-Wheel System Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Remove the instrument panel cluster panel. 3. Remove the air suspension control module screws. 4. Remove the air suspension control module and bracket assembly. 1. Disconnect the electrical connectors. 2. Remove the air suspension control module and bracket assembly. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Note: The air suspension control module is calibrated with information from the ride height sensor. A new or exchanged air suspension control module requires that the ride height adjustment calibration process be performed; refer to Front Ride Height Resetting - Clear B2140 DTC. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Front Height Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Front Height Sensor > Page 7023 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Rear Ride Height Sensor: Service and Repair Rear Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Note: The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. Remove the air suspension height sensor. 1. Disconnect the electrical connector. 2. Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Rear > Page 7026 Ride Height Sensor: Service and Repair 4-Wheel System Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Note: The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. Remove the air suspension height sensor. 1. Disconnect the electrical connector. 2. Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications Suspension Mode Switch: Specifications Air Suspension Switch Bracket Mounting Bolt .................................................................................................................. 10.2-13.8 Nm (91-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair > Rear Only System Suspension Mode Switch: Service and Repair Rear Only System Removal 1. Disconnect the battery ground cable. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. 4. Disconnect the air suspension switch electrical connector. 5. Remove the air suspension switch bracket mounting bolt. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair > Rear Only System > Page 7035 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair > Rear Only System > Page 7036 Suspension Mode Switch: Service and Repair 4-Wheel System Removal 1. Disconnect the battery ground cable. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. 4. Disconnect the air suspension switch electrical connector. 5. Remove the air suspension switch bracket mounting bolt. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair > Rear Only System > Page 7037 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair Center Link: Service and Repair Removal and Installation 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the steering sector shaft arm drag link castellated nuts. 1. Remove the cotter pins. 2. Remove the castellated nuts. 3. On 4x2 vehicles, remove the steering sector shaft arm drag link. - Use the special tool to separate the steering sector shaft arm drag link from the RH tie-rod end, the steering idler arm and bracket, the steering gear sector shaft arm and the LH tie-rod end. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Page 7042 4. On 4x4 vehicles, remove the tie-rod ends from the steering sector shaft arm drag link. - Use the Separator to separate the steering sector shaft arm drag link from RH and LH tie-rod ends. 5. On 4x4 vehicles, remove the steering sector shaft arm drag link. - Use the special tool to remove the steering sector shaft arm drag link. 6. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Diagnostic Connector, Steering > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Technical Service Bulletins > Idler Arm - Replacement Specifications Idler Arm: Technical Service Bulletins Idler Arm - Replacement Specifications Article No. 02-4-1 02/15/02 STEERING - IDLER ARM REPLACEMENT SPECIFICATIONS FORD: 2000-2002 EXPEDITION, F-150 LINCOLN: 2000-2002 NAVIGATOR 2002 BLACKWOOD ISSUE A high number of Idler Arms are being replaced as a result of routine inspections or of complaints of tire wear and looseness being felt in the steering system. There may be a misunderstanding about how much Idler Arm movement/play is acceptable - because there is no movement/free-play specification published in the Workshop Manual or any other dealer Service Information documents. ACTION Use proper inspection practices referred to in the following Service Procedure for measuring Idler Arm freeplay. The maximum allowable freeplay is 5 mm (0.200"). Refer to the following Service Procedure for the correct Idler Arm inspection details. SERVICE PROCEDURE 1. Place the vehicle on a drive-on hoist. 2. Obtain a dial indicator and holding fixture similar to that referenced in the Figures shown (a magnetic-base dial indicator is also acceptable - provided it mounts securely). 3. Clean off the area on the Center Link next to the Idler Arm mount. 4. Install and zero-out the dial indicator on the Center Link. 5. While grasping the Center Link, and attempting to move it up and down; observe the dial indicator reading. 6. If the reading is 5 mm (0.200") or less, the Idler Arm movement is acceptable, and the Idler Arm should not be replaced. 7. If the reading is greater than 5 mm (0.200"), replace the Idler Arm. 8. Check and adjust toe-in as necessary if the Idler Arm is replaced. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Technical Service Bulletins > Idler Arm - Replacement Specifications > Page 7050 ^ Figure # 1 shows one type of tool in position on a 4X4 vehicle ^ Figure # 2 shows the tip of the dial indicator resting on the Center Link adjacent to the Idler Arm attachment point ^ Figure # 3 shows one type of tool in position on a 4X2 vehicle Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Technical Service Bulletins > Idler Arm - Replacement Specifications > Page 7051 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 020401A Measure Idler Arm 0.2 Hr. Freeplay 020401B Measure Idler Arm 1.2 Hrs. Freeplay And Replace Idler Arm (Includes Time To Check And Adjust Toe As Necessary DEALER CODING CONDITION BASIC PART NO. CODE 3355 33 OASIS CODES: 303000, 306000, 390000, 702000, 702100 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Technical Service Bulletins > Page 7052 Idler Arm: Specifications Steering Idler Arm And bracket To Frame Bolt (2 Req'd) .................................................................................................................... 200 Nm (148 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Technical Service Bulletins > Page 7053 Idler Arm: Service and Repair Special Tool(s) Removal and Installation 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the steering sector shaft arm drag link castellated nuts. 1. Remove the cotter pins. 2. Remove the castellated nut. 3. Use the special tool to separate the steering sector shaft arm drag link. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Technical Service Bulletins > Page 7054 4. Remove the steering idler arm and bracket. 1. Remove the bolts. 2. Remove the steering idler arm and bracket. 5. To install, reverse the removal procedure. - The idler arm has two grease fittings. Lubricate with Premium Long-Life Grease XG-1-K or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Specifications Pitman Arm: Specifications Steering Gear Sector Shaft Arm To Sector Shaft Nut ........................................................................................................................ 275 Nm (203 ft. lbs.) Steering Sector Shaft Arm Drag Link To Inner Tie Rod End Castellated Nut (2 Req'd) .......................................................................... 90 Nm (66 ft. lbs.) Steering Sector Shaft Arm Drag Link To Steering Gear Sector Shaft Arm Castellated Nut .................................................................... 90 Nm (66 ft. lbs.) Steering Sector Shaft Arm Drag Link To Steering Idler Arm Castellated Nut ......................................................................................... 90 Nm (66 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Specifications > Page 7058 Pitman Arm: Service and Repair Removal and Installation 1. Note: The steering gear must be removed from the vehicle to remove the sector shaft arm. Remove the steering gear. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Special Tools Note: If the air is not purged from the power steering system correctly, pump failure could result. This condition can occur on pre-delivery vehicles with evidence of aerated fluid or on vehicles that have had steering component repairs. A whine heard from the power steering pump may be caused by air in the system. The power steering purging procedure must be performed under the following conditions: Prior to any component repair for which power steering noise complaints are accompanied by evidence of aerated fluid. - After replacement of any power steering system component (gear, hose, etc.). 1. Remove the power steering fluid reservoir cap. 2. Tightly insert the stopper of the special tool into the power steering fluid reservoir. 3. Start the engine and allow it to idle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 7063 4. Using the special tool, apply the maximum vacuum source for a minimum of three minutes with the engine at idle. Maintain the maximum vacuum. 5. Release the vacuum source and remove the special tool. 6. WARNING: Do not mix oil types. Any mixture or any unapproved oil could lead to seal deterioration and leaks. A leak could ultimately cause loss of fluid, which could result in a loss of power steering assist. Fill the power steering reservoir to the appropriate level. Use Motorcraft MERCON Multi-Purpose Transmission Fluid, XT-2-QDX or equivalent meeting Ford specification MERCON. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 7064 7. Using the special tool, apply maximum vacuum. 8. CAUTION: Do not hold the steering wheel in the far left or right position or damage to power steering may result. Cycle the steering wheel from stop to stop every 30 seconds for approximately five minutes. 9. Stop the engine, release the vacuum source, and remove the special tool. 10. Add power steering fluid if necessary. Install the power steering fluid reservoir cap. 11. CAUTION: Do not hold the steering wheel in the far left or right position or damage to power steering may result. Start the engine and cycle the steering wheel from stop to stop every 30 seconds for approximately five minutes. 12. Check for power steering fluid leaks at all connections. If the power steering fluid still shows signs of aeration, repeat this procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 7069 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 7070 Power Steering Fluid: Specifications / / Power Steering Fluid Type MERCON(R) ATF Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Service and Repair > Fill Power Steering Fluid: Service and Repair Fill 1. WARNING: Do not mix oil types. Any mixture or any unapproved oil could lead to seal deterioration and leaks. A leak could ultimately cause loss of fluid, which could result in a loss of power steering assist. Fill the power steering reservoir to appropriate level. Use Motorcraft MERCON Multi-Purpose Transmission Fluid, XT-2-QDX or equivalent meeting Ford specification MERCON. 2. Remove the ignition coil fuse number 30 in the fuse junction panel to disable the engine from starting. 3. Raise the front wheels off the floor. 4. CAUTION: Do not operate the starter motor for more than 10 seconds at a time. Damage to the starter motor could result. Turn the steering wheel from stop to stop while cranking the engine. 5. Lower the vehicle. 6. WARNING: Do not mix oil types. Any mixture or any unapproved oil could lead to seal deterioration and leaks. A leak could ultimately cause loss of fluid, which could result in a loss of power steering assist. CAUTION: Do not overfill the power steering fluid reservoir. Fill the power steering fluid reservoir to the appropriate level. Use Motorcraft MERCON Multi-Purpose Transmission Fluid, XT-2-QDX or equivalent meeting Ford specification MERCON. 7. Install the ignition coil fuse number 30 in the fuse junction panel fuse box. 8. Note: If the power steering is noisy and accompanied by evidence of aerated fluid, it will be necessary to purge the power steering system. Clear the Diagnostic Trouble Codes (DTCs). Run vehicle and check the system for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Service and Repair > Fill > Page 7073 Power Steering Fluid: Service and Repair System Flushing WARNING: Do not mix oil types. Any mixture or any unapproved oil could lead to seal deterioration and leaks. A leak could ultimately cause loss of fluid, which could result in a loss of power steering assist. 1. Remove the ignition coil fuse number 30 in the fuse junction panel to disable the engine from starting. 2. Disconnect the power steering return hose. 1. Compress and move the hose clamp. 2. Disconnect the power steering return hose and plug the fitting to the reservoir. 3. Attach an extension hose between the power steering return hose and an empty container. 4. WARNING: Do not mix oil types. Any mixture or any unapproved oil could lead to seal deterioration and leaks. A leak could ultimately cause loss of fluid, which could result in a loss of power steering assist. Fill the power steering fluid reservoir to the appropriate level. Use Motorcraft MERCON Multi-Purpose Transmission Fluid, XT-2-QDX or equivalent MERCON approved fluid. 5. Raise the front wheels off the ground. 6. CAUTION: Do not operate the starter motor for more than 10 seconds at a time. Damage to the starter motor could result. Turn the steering wheel from stop to stop while cranking the engine until the fluid exiting the extension hose is clean. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Service and Repair > Fill > Page 7074 7. Disconnect the extension hose from the power steering return hose and attach the power steering return hose to the power steering fluid reservoir. 8. WARNING: Do not mix oil types. Any mixture or any unapproved oil could lead to seal deterioration and leaks. A leak could ultimately cause loss of fluid, which could result in a loss of power steering assist. CAUTION: Do not overfill the power steering fluid reservoir. Fill the power steering fluid reservoir to the appropriate level. Use Motorcraft MERCON Multi-Purpose Transmission Fluid, XT-2-QDX or equivalent MERCON approved fluid. 9. Install the ignition coil fuse. 10. CAUTION: Do not hold the steering wheel against the stops for more than five seconds; damage to the power steering pump may occur. Start the engine and turn the steering wheel from stop to stop. 11. Note: If power steering is noisy and accompanied by aerated fluid, it will be necessary to purge the power steering system. Check the power steering fluid level. 12. Clear Diagnostic Trouble Codes (DTCs). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 Removal 1. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. If equipped, remove the skid plate. 1. Remove the bolts. 2. Remove the skid plate. 3. Remove the lower radiator air deflector. 1. Remove the screws. 2. Remove the push clips. 3. Remove the lower radiator air deflector. 4. Disconnect the power steering fluid cooler hoses. 1. Compress and slide the clamps back. 2. Disconnect the hoses. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Page 7078 5. Remove the power steering fluid cooler. 1. Remove the bolts. 2. Remove the fluid cooler. Installation 1. Follow the removal procedure in reverse order. 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 Removal 1. Remove the three bolts. Position the power steering pump reservoir aside. 2. Disconnect the hoses. Drain the power steering system. 3. Remove the power steering pump reservoir. Installation 1. Follow the removal procedure in reverse order. 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Power Steering Pressure Hose Fitting ............................................................................................................................................ 17-23 Nm (13-17 ft. lbs.) Power Steering Return Hose Fitting ............................................................................................................................................... 17-23 Nm (13-17 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Power Steering Low Pressure Power Steering Line/Hose: Service and Repair Hose - Power Steering Low Pressure Removal 1. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the power steering low pressure hose. Drain the power steering system. 3. Lower the vehicle. 4. Disconnect and remove the power steering low pressure hose. Installation 1. Follow the removal procedure in reverse order. 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Power Steering Low Pressure > Page 7087 Power Steering Line/Hose: Service and Repair Hose - Power Steering Pressure Special Tool(s) Removal 1. Prepare the vehicle for power steering pressure hose removal. 1. Remove the fan and shroud. 2. Remove the drive belt. 2. Disconnect the power steering pressure hose. Drain the power steering system. 3. Remove the power steering pump pulley using the Power Steering Pump Pulley Remover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Power Steering Low Pressure > Page 7088 4. Disconnect and remove the power steering pressure hose. Installation 1. Install a new seal on the power steering pressure hose at the power steering pump end. - Remove and discard the original seal. - Stretch the seal over the Seal Replacer until it is large enough to slip over the tube nut. 2. Route the power steering pressure hose in the vehicle. Connect the power steering pressure hose. 3. CAUTION: Replacement of the power steering pump pulley is necessary after being removed and installed two times. Install the power steering pump pulley. Inspect the pulley for paint marks in the web area near the hub. If there are two paint marks, replace the pulley. If there is no paint or one paint mark, use a paint pencil to mark the web area of the pulley near the hub. - Use the Power Steering Pump Pulley Replacer. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Power Steering Low Pressure > Page 7089 4. Connect the power steering pressure hose. 5. Restore the vehicle to operating condition. 1. Install the drive belt. 2. Install the fan and shroud. 3. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Power Steering Low Pressure > Page 7090 Power Steering Line/Hose: Service and Repair Hose - Power Steering Reservoir Pump Removal 1. Prepare the vehicle for power steering reservoir pump hose removal. 1. Remove the fan and shroud. 2. Remove the drive belt. 2. Remove the three bolts. 3. Disconnect the power steering reservoir pump hose. Drain the power steering system. 4. Remove the nuts and belt deflector. 5. Remove the two bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Power Steering Low Pressure > Page 7091 6. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in shifting of the vehicle during these operations. Raise and support the vehicle. 7. Disconnect the Electronic Variable Orifice (EVO) power steering control valve actuator electrical connector. 8. Remove the bolt. 9. Lower the vehicle. 10. Position the power steering pump forward. 11. Disconnect and remove the power steering reservoir pump hose. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Power Steering Low Pressure > Page 7092 Installation 1. Route the power steering reservoir pump hose in the vehicle. Connect the power steering reservoir pump hose. 2. Position the power steering pump. 3. Loosely install the bolts. 4. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in shifting of the vehicle during these operations. Raise and support the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Power Steering Low Pressure > Page 7093 5. Install the bolt. 6. Connect the EVO power steering control valve actuator electrical connector. 7. Lower the vehicle. 8. Tighten the bolts. 9. Install the belt deflector and nuts. 10. Connect the power steering reservoir pump hose. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Power Steering Low Pressure > Page 7094 11. Position the power steering pump reservoir. Install the three bolts. 12. Restore the vehicle to operating condition. 1. Install the drive belt. 2. Install the fan and shroud. 3. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Power Steering Low Pressure > Page 7095 Power Steering Line/Hose: Service and Repair Hose - Power Steering Return Removal 1. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the power steering return hose. Drain the power steering system. 3. Lower the vehicle. 4. Disconnect and remove the power steering return hose. Installation 1. Follow the removal procedure in reverse order. 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Power Steering Pressure Hose Fitting ............................................................................................................................................ 17-23 Nm (13-17 ft. lbs.) Power Steering Return Hose Fitting ............................................................................................................................................... 17-23 Nm (13-17 ft. lbs.) Power Steering Pump Lower Bolt .................................................................................................................................................. 20-30 Nm (15-20 ft. lbs.) Power Steering Pump Upper Bolts ................................................................................................................................................. 20-30 Nm (15-20 ft. lbs.) Reservoir Bracket Bolts To Exhaust Manifold .............................................................................................................................. 68-92 Nm (50-67 ft. lbs.) Upper Reservoir Bracket Bolt .................................................................................................................................................... 9-12 Nm (80-107 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 7100 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Flow ..................................................................................................................................................... ............ 3.0 ± 0.2 gpm @ 50 psi & 2500 Pump RPM Minimum Capacity ............................................ ....................................................................................................................................... 1.4 gpm @ 750 psi Relief Pressure ....................................................................................................................... ......................................................................... 1300-1430 psi Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 7101 Power Steering Pump: Description and Operation The steering gear has the following features: It is a torsion-bar type hydraulic assisted system. - It reduces road shock and vibration. - It includes a rotary-style hydraulic valve. - It uses a dot matrix ID mark on the gear housing between the valve housing and the sector shaft housing cover. - It may have an optional identification tag mounted to the valve housing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Power Steering Pump: Service and Repair Power Steering Pump Removal 1. Prepare the vehicle for power steering pump removal. 1. Remove the fan and shroud. 2. Remove the drive belt. 2. Remove the three bolts. Position the power steering pump reservoir aside. 3. Disconnect the power steering reservoir pump hose. Drain the power steering pump supply line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7104 4. Disconnect the power steering pressure hose. Drain the power steering system. 5. Remove the nuts and belt deflector. 6. Remove the two bolts. 7. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle, this can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in shifting of the vehicle during these operations. Raise and support the vehicle. 8. If equipped, remove the skid plate. 1. Remove the bolts. 2. Remove the skid plate. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7105 9. Disconnect the Electronic Variable Orifice (EVO) power steering control valve actuator electrical connector. 10. Remove the bolt. 11. Lower the vehicle. 12. Remove the power steering pump. 13. Remove the power steering reservoir pump hose and the power steering pressure hose. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7106 14. Position the power steering pump in a vise. Remove the power steering pump pulley using the Power Steering Pump Pulley Remover. 15. Remove the pump from the vise. Installation 1. CAUTION: Replacement of the power steering pump pulley is necessary after being removed and installed two times. Inspect the pulley for paint marks in the web area near the hub. If there are two paint marks, replace the pulley. If there is no paint or one paint mark, use a paint pencil to mark the web area of the pulley near the hub. Position the power steering pump in a vise. Install the power steering pump pulley. Use the Power Steering Pump Pulley Replacer. - Remove the pump from the vise. 2. Install a new seal on the power steering pressure hose at the power steering pump end. - Remove and discard the original seal. - Stretch the seal over the Seal Replacer until it is large enough to slip over the tube nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7107 3. Install the power steering reservoir pump hose and the power steering pressure hose. 4. Position the power steering pump in the vehicle. 5. Loosely install the two bolts. 6. Raise and support the vehicle. 7. Install the bolt. 8. Connect the EVO power steering control valve actuator electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7108 9. If equipped, install the skid plate. 1. Position the skid plate. 2. Install the bolts. 10. Lower the vehicle. 11. Tighten the two bolts. 12. Install the belt deflector and nuts. 13. Connect the power steering pressure hose. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7109 14. Connect the power steering reservoir pump hose. 15. Position the power steering oil reservoir. Install the three bolts. 16. Restore the vehicle to operating condition. 1. Install the drive belt. 2. Install the fan and shroud. 3. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7110 Power Steering Pump: Service and Repair Power Steering Pump Pulley Special Tool(s) Removal 1. Prepare the vehicle for power steering pump pulley removal. 1. Remove the fan and shroud. 2. Remove the drive belt. 2. Remove the power steering pump pulley using the Power Steering Pump Pulley Remover. Installation 1. CAUTION: Replacement of the power steering pump pulley is necessary after being removed and installed two times. Install the power steering pump pulley. Inspect the pulley for paint marks in the web area near the hub. If there are two paint marks, replace the pulley. If there is no paint or one paint mark, use a paint pencil to mark the web area of the pulley near the hub. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 7111 - Use the Power Steering Pump Pulley Replacer. 2. Restore the vehicle to operating condition. 1. Install the drive belt. 2. Install the fan and shroud. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Diagrams > Air Suspension/Electronic Variable Orifice Steering Module Steering Control Module: Diagrams Air Suspension/Electronic Variable Orifice Steering Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Diagrams > Air Suspension/Electronic Variable Orifice Steering Module > Page 7117 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Air Suspension/Electronic Variable Orifice Steering Module Steering Control Module: Diagrams Air Suspension/Electronic Variable Orifice Steering Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Diagrams > Air Suspension/Electronic Variable Orifice Steering Module > Page 7124 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Supplemental Restraint System ( SRS ) Depowering and Repowering Depowering Procedure Warning: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Warning: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F22 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. Warning: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 6. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 1. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse F22 (10A) to the CJB and close the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 4. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7137 The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Deactivation and Reactivation Supplemental Restraint System ( SRS ) Deactivation and Reactivation Special Tool(s) Deactivation Warning: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Warning: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. Warning: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Warning: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. Warning: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All Vehicles 1. Move and tilt the front seats to their highest and most forward position. 2. Turn all vehicle accessories OFF. 3. Turn the ignition switch to OFF. 4. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F22 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 5. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 6. Turn the ignition OFF. Warning: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7138 The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 7. Disconnect the battery ground cable (14301) and wait at least one minute. 8. Remove the two steering wheel back cover plugs. 9. Remove the two driver air bag module retaining bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7139 10. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Disconnect the horn switch electrical connector. 3. Remove the driver air bag module. 11. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7140 12. Remove the instrument panel relay cover. 13. Disconnect the passenger air bag module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7141 14. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicle without side airbags Caution: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. 15. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM) If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with side airbags 16. Disconnect the passenger seat side air bag electrical connector. 1. Slide and disengage the passenger seat side air bag electrical connector locking clip. 2. Push in to release the tab and disconnect the passenger seat side air bag electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7142 17. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 18. Disconnect the driver seat side air bag electrical connector. 1. Slide and disengage the driver seat side air bag electrical connector locking clip. 2. Push in to release the tab and disconnect the driver seat side air bag electrical connector. 19. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All Vehicles 20. Install the RCM fuse F22 (10A) to the CJB. 21. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7143 Reactivation All Vehicles 1. Remove the RCM fuse F22 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles with side airbags 3. Remove the restraint system diagnostic tool from the driver side seat air bag floor electrical connector. 4. Connect the driver seat side air bag electrical connector. 1. Connect the driver seat side air bag electrical connector. 2. Slide and engage the driver seat side air bag electrical connector locking clip. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7144 5. Remove the restraint system diagnostic tool from the passenger side seat air bag floor electrical connector. 6. Connect the passenger side seat air bag electrical connector. 1. Connect the passenger side seat air bag electrical connector. 2. Slide and engage the passenger side seat air bag electrical connector locking clip. All Vehicles 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7145 8. Connect the passenger air bag module electrical connector. 9. Install the instrument panel relay cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7146 10. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Connect and position the driver air bag module. 1. Connect the horn switch electrical connector. 2. Connect the driver air bag module electrical connector. 3. Position the driver air bag module to the steering wheel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7147 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 14. 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. 15. Turn the ignition switch from OFF to ON. 16. Install the RCM fuse F22 (10A) to the CJB and close the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 17. Connect the battery ground cable. 18. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 7148 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Is the air bag system connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Are the side air bag electrical connectors beneath the front seats connected? 4. Is the Restraints Control Module (RCM) connected? 5. Is the vehicle battery connected? Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Steering Gear: Specifications Static Steering Wheel Turning Effort ................................................................................................................................................... 2.0 Nm (18 inch lbs.) Total Meshload Over Worm Bearing Preload ........................................................................................................... 0.45-1 Nm (4-9 inch lbs.) (Over Ends) Turning Effort ............................................................................................................................ ............................................................... 2.72 KG (6.0 lbs.) Turns Of Steering Wheel (Lock To Lock-Linkage Disconnected) .................................................................................................................................... 3.4 Ratio ......... .............................................................................................................................................................. ......................................................... 14:1 Steering Gear Type ........................................................... .................................................................................................... Recirculating Ball Torsion Bar Worm Bearing Preload ........................................................................................................................ ......................................... 0.9 Nm (8 inch lbs.) Max. Meshload Adjuster Locknut Torque ..................................................................................................................................... 26.3-35 Nm (19.3-25.7 ft. lbs.) Steering Sector Shaft Arm Drag Link Castellated Nut Torque .................................................................................................... 77-103 Nm (57-75 ft. lbs.) Sector Shaft Arm Nut ............................................................................................................................................................. 234-316 Nm (173-233 ft. lbs.) Sector Shaft Housing Cover Bolts .............................................................................................................................................. 61-75 Nm (45-55 ft. lbs.) Ball Guide Clamp Bolts .......................................................................................... ........................................................................ 5-7 Nm (45-62 inch lbs.) Intermediate Shaft Pinch Bolt ........................................................................................................................................................ 40-54 Nm (30-40 ft. lbs.) Power Steering Gear Race Nut ..................................................................................................................................................... 75-122 Nm (55-90 ft. lbs.) Steering Gear Allen Head Race Lock Nut .......................................................................................................................... 1.7-2.8 Nm (15-24.9 inch lbs.) Steering Gear Bolts .............................................................................................................. .......................................................... 68-92 Nm (50-67 ft. lbs.) Power Steering Pressure Hose Fitting ............................................................................................................................................ 17-23 Nm (13-17 ft. lbs.) Power Steering Return Hose Fitting ............................................................................................................................................... 17-23 Nm (13-17 ft. lbs.) Valve Housing Bolts ............................................................................................... ....................................................................... 40-60 Nm (30-44 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7152 Steering Gear: Description and Operation Note: Earlier builds have four bolts mounting the power steering pump to the engine block. The fourth lower bolt behind the pulley on earlier builds may be discarded upon removal of the power steering pump. The CIII power steering pump has the following features: It is a belt-driven, vane-type, power steering pump. - It is mounted directly to the engine block by three bolts. - The power steering pump is replaced as an assembly. - The identification tag attached to the power steering pump indicates the model number and bar code. Refer to these when pump replacement is required. - The power steering pump uses a quick connect fitting for the power steering pressure hose. - The power steering fluid reservoir is mounted on the LH side of the engine. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7153 Steering Gear: Testing and Inspection Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. Rotate the steering wheel to the RH stop, then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. 4. Turn the steering wheel another 90°, Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200 Hz) shudder is present, this is a normal steering system condition. 7. If a loud grunt is heard or a strong shudder is felt, fill and purge the power steering system. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7154 Steering Gear: Adjustments Special Tool(s) MESHLOAD ADJUSTMENT 1. Note: The engine should not be running. Turn the steering wheel from right stop to left stop at least once. 2. Remove the driver side air bag. 3. Raise and support the vehicle. 4. Remove the steering sector shaft arm drag link castellated nut. 1. Remove the cotter pin. 2. Remove the castellated nut. 5. Using the special tool, separate the steering sector shaft arm drag link. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7155 6. Note: The front wheels should not touch the ground. Lower and support the front of the vehicle. 7. Note: Measure the torque to turn in the 90' arc just prior to end of travel. Attach a inch lbs. torque wrench to the (A) bolt and measure the steering gear meshload from center. 8. Meshload adjustment is necessary if out of specification. - Adjust meshload as required to obtain center torque greater than end torque. 9. Remove the fan blade assembly and fan shroud to access the sector shaft locknut. 10. Adjust the sector shaft to proper rotating torque. 1. Hold the sector shaft and loosen the meshload adjuster locknut. 2. Adjust the sector shaft screw. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 7156 11. Verify that the static steering wheel turning effort is to specification. - Readjust if necessary. 12. Note: Do not overtighten locknut. Tighten the meshload adjuster locknut. 1. Hold the sector shaft screw. 2. Tighten the locknut to specification. 13. Install the steering sector shaft arm drag link castellated nut and cotter pin. 1. Position the steering sector shaft arm drag link. 2. Install the steering sector shaft arm drag link castellated nut. 3. Install a new cotter pin. 14. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 15. Install the fan blade assembly and fan shroud. 16. Install the driver side air bag. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation Steering Gear: Service and Repair Removal and Installation Special Tool(s) Removal 1. WARNING: The electrical power to the air suspension must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the skid plates, if equipped. 1. Remove the bolts. 2. Remove the skid plate. 3. Slide back the plastic cover from the intermediate steering shaft to the steering gear. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 7159 4. Remove the intermediate shaft pinch bolt and remove the intermediate steering shaft from the steering gear. 5. Remove the steering shaft arm drag link castellated nut. 1. Remove the cotter pin. 2. Remove the castellated nut. 6. Use the Pitman Arm Puller to separate the steering sector shaft arm drag link. 7. Mark a reference point between the steering gear sector shaft and the steering gear housing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 7160 8. Disconnect the power steering lines at the steering gear. 9. Remove the steering gear to frame mounting bolts and remove the steering gear. - Note the location of each bolt during removal. 10. Secure the steering gear in a vise. Remove the nut and lockwasher. 11. Use the Pitman Arm Puller to remove the steering gear sector shaft arm. - Note the position of the steering gear sector shaft arm. Installation 1. Note: The steering gear sector shaft arm to sector shaft nut must be installed and tightened to specification prior to installation of the steering gear for clearance purposes. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 7161 Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 7162 2. Fill and bleed the power steering system and check for leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 7163 Steering Gear: Service and Repair Disassembly and Assembly Special Tool(s) (Part 1) Special Tool(s) (Part 2) Disassembly Note: The steering gear input shaft and seals cannot be repaired or replaced separately. Gear replacement may be necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 7164 1. Secure the steering gear in a vise with the indexing flat pointed down. Use protective caps on the vise jaws. 2. Rotate the power steering gear input shaft and control from stop to stop and then center the gear. 3. Remove the steering gear sector shaft housing cover bolts. 4. Tap on the lower end of the steering gear sector shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 7165 5. Remove the steering gear sector shaft. 6. Remove the locking nut from the steering gear sector shaft adjustment screw. 7. Remove the sector shaft housing cover. - Hold the steering gear sector shaft. - Turn the housing cover counterclockwise. 8. Remove the valve housing bolts and the identification tag. 9. Remove the valve housing and piston assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 7166 10. Remove and discard the gasket. 11. Remove the ball bearings. 1. Remove the bolts. 2. Remove the steering gear ball return guide clamp. 3. Remove the steering gear ball return guide. 4. Rotate the piston over a container to collect the 28 steering gear worm balls. 12. Remove the input shaft valve and housing assembly from the piston. 13. Remove and discard the seal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 7167 14. Install the valve housing in Bench Mounted Holding Fixture and loosen the setscrew. 15. Use Adjuster and Locknut Wrench to remove the race nut. 16. Remove the power steering gear input shaft and control from the valve housing. 17. Rotate the valve housing with Bench Mounted Holding Fixture. 18. Use Puller to remove the power steering gear input shaft seal dust seal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 7168 19. Remove the input shaft snap ring. 20. Rotate the valve housing with Bench Mounted Holding Fixture and use Input Shaft Bearing/Seal Tool to remove the bearing and power steering gear input shaft seal. 21. Remove the valve housing from Bench Mounted Holding Fixture. 22. Install the steering gear housing in Bench Mounted Holding Fixture and remove the steering gear sector shaft dust seal from the sector shaft seal bore. 23. Remove the spacer. 1. Remove the snap ring. 2. Remove the spacer. 24. Note: The steering gear sector shaft bearing is not replaceable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 7169 Use Puller to remove the sector shaft seal. Assembly 1. Lubricate the sector shaft seal bore. - Use Multi-Purpose Grease DOAZ-195 84-AA or equivalent meeting Ford specifications ESB-MlC93-B and ESR-MIC159-A. 2. Use Sector Shaft Seal Replacer to install the sector shaft seal. - Lubricate the sector shaft seal, use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-MIC159-A. 3. Install the spacer. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 7170 4. Install the snap ring. 5. Note: Place the steering gear sector shaft dust seal on Sector Shaft Seal Replacer so the raised lip is toward the tool. Use Sector Shaft Seal Replacer to install the sector shaft dust seal. Lubricate the steering gear sector shaft dust seal; use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-MIC93-B and ESR-MIC159-A. 6. Remove the steering gear housing from Bench Mounted Holding Fixture. 7. Position the input shaft bearing in the valve housing and use Input Shaft Bearing/Seal Tool Set and a press to seat the bearing. 8. Use Input Shaft Bearing/Seal Tool and a press to seat the power steering gear input shaft seal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 7171 9. Install the input shaft snap ring. 10. Use Input Shaft Bearing/Seal Tool to install the power steering gear input shaft dust seal. 11. Mount the valve housing in Bench Mounted Holding Fixture. 12. Install the power steering gear input shaft and control into the valve housing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 7172 13. Position the power steering gear race nut into the valve housing. 14. Use Adjuster and Locknut Wrench to tighten the race nut. 15. Install the setscrew. 16. Remove the valve housing from Bench Mounted Holding Fixture and position the piston on the worm gear. 17. WARNING: Hold the ball return guides until the cap or clip is reinstalled. failure to hold the guides will result in a trapped ball or balls, which could cause a vehicle accident. If the ball guides become unseated at any time, remove all the balls and repeat the procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 7173 Install the steering gear ball return guide on the piston. 18. WARNING: The correct number of balls are required for proper gear operation. count the balls and insert each carefully. WARNING: To make sure the balls are properly installed, rotate the steering gear input worm gear and rack from one end of travel to the other without allowing the poppet adjuster to contact the valve housing or moving the valve housing pilot face more than 69.1 mm (2-3/4 inches) from the input end of the rack piston. If the steering gear input worm gear and rack cannot be rotated, reinstall the balls. If a steering gear is installed with a steering gear input worm gear and rack that cannot rotate, the steering gear will not function correctly and steering and gear failure can result. Rotate the piston while holding the steering gear ball return guide and install the 28 ball bearings into the opening in the ball guide. 19. Install the steering gear ball return guide clamp. 1. Position the steering gear ball return guide clamp. 2. Install the bolts. 20. Install a new gasket. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 7174 21. Lubricate and install the seal on the piston. - Use Multi -Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-MlC93-B and ESR-MlCl59-A. 22. Note: Make sure to align the oil passages in the steering gear housing. Install the piston assembly into the steering gear housing. 23. Rotate the teeth so they are on the same plane as the steering gear sector shaft. 24. Loosely install the valve housing bolts and the identification tag, if so equipped. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 7175 25. Lubricate the O-ring on the sector shaft housing cover. - Use Multi-Purpose Grease DOAZ-19584-AA or equivalent meeting Ford specifications ESB-M1C93-B and ESR-M1C159-A. 26. Rotate the housing clockwise and install the sector shaft into the sector shaft housing. 27. Note: The sector shaft lock nut will be tightened during the steering gear meshload adjustment. Install the sector shaft lock nut. 28. Note: Loosely install the sector shaft housing bolts. Install the sector shaft and housing assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal and Installation > Page 7176 29. Tighten the bolts. 30. Tighten the bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose Steering Wheel: Customer Interest Interior - Leather Wrapping On Steering Wheel Is Loose TSB 07-4-3 03/05/07 LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty 2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape Hybrid 2007 Edge 2004-2007 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 04-24-3 to update the vehicle model years. ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area. ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL. CAUTION AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 7185 1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B. 2. Fold loose leather out of the way. 3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke. 4. Fold the leather back into its original position. 5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to the wheel spoke (apply pressure for at least 30 seconds). NOTE THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE REPAIR AREA. 6. Reinstall steering wheel. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070403 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 3600 33 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose Steering Wheel: All Technical Service Bulletins Interior - Leather Wrapping On Steering Wheel Is Loose TSB 07-4-3 03/05/07 LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty 2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape Hybrid 2007 Edge 2004-2007 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 04-24-3 to update the vehicle model years. ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area. ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL. CAUTION AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering Wheel Is Loose > Page 7191 1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B. 2. Fold loose leather out of the way. 3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke. 4. Fold the leather back into its original position. 5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to the wheel spoke (apply pressure for at least 30 seconds). NOTE THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE REPAIR AREA. 6. Reinstall steering wheel. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070403 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 3600 33 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7192 Steering Wheel: Service and Repair Special Tool(s) Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged trim covers must be replaced, not repainted. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Note: Make sure the front wheels are in the straight-ahead position. Disconnect the battery cables. 1. Disconnect the battery ground cable and wait at least one minute. 2. Disconnect the battery to starter relay cable and wait one minute for the backup power supply to be depleted. 2. Remove the driver side air bag module. 1. Remove the two screws. 2. Disconnect the air bag sliding contact electrical connector. 3. Disconnect the horn electrical connector. 4. Remove the driver side air bag module. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7193 3. Remove the steering wheel bolt. 4. CAUTION: Removing the steering wheel without using a puller can damage the column bearings. Use the Differential Side Bearing Puller to remove the steering wheel. Installation WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged trim covers must be replaced, not repainted. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged Supplemental Restraint System (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag Supplemental Restraint System (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 7194 1. Install the steering wheel. 1. Position the steering wheel. 2. Install the bolt. 2. Install the driver side air bag module. 1. Connect the air bag sliding contact electrical connector. 2. Connect the horn electrical connector. 3. Position the driver side air bag module. 4. Install the two screws. 3. Connect the battery cables. 1. Connect the battery to starter relay cable. 2. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Tie Rod End Inspection Procedures Tie Rod End: Technical Service Bulletins Steering - Tie Rod End Inspection Procedures Article No. 03-15-13 08/04/03 STEERING - TIE ROD END INSPECTION PROCEDURE FORD: 1997-2002 EXPEDITION 1997-2003 F-150 2001-2004 ESCAPE LINCOLN: 1998-2002 NAVIGATOR 2002-2003 BLACKWOOD This article supersedes 03-9-9 to update the vehicle models covered. ISSUE This article is to be used as an updated procedure for inspecting tie rod end wear. ACTION This procedure is designed to supplement the Workshop Manual, as it provides a more detailed tie rod end inspection procedure. SERVICE INFORMATION NOTE FOR ESCAPE VEHICLES, THIS TIE ROD END INSPECTION PROCEDURE SHOULD ONLY BE COMPLETED ON THE OUTER TIE RODS. FOR ESCAPE INNER TIE ROD INSPECTION PROCEDURES, REFER TO WORKSHOP MANUAL SECTION 211-00. Step 1 - Free Play: Check the outer tie rod ends by grasping by hand and push up and down. Check the inner tie rod ends, pushing them front to rear. If any free play is observed in a joint, it is worn and should be replaced. Step 2 - Stud Lash - Free Play: While vehicle is on the ground or on a drive-on hoist, have an assistant rotate the steering wheel rapidly back and forth from 10 o'clock to 2 o'clock to 10 o'clock while observing the inner and outer tie rods. If the outer tie rod ends have any vertical movement or the inner tie rod ends have any horizontal movement, the tie rod end with the observed movement should be replaced. Step 3 - Seal Inspection: Raise the vehicle on a hoist and remove the front wheels. The wheels will need to be turned to the right in order to inspect the passenger side inner tie rod end and to the left to inspect the drivers side inner tie rod end. Inspect all four seals for tears, perforations and wear. If there is any indication of wear or perforations on the seal, that tie rod end should be replaced. Step 4 - Stud Corrosion: For Escape Vehicles - If Squeak is noticed during Step 2, disconnect tie rod from knuckle and articulate stud in socket. If squeak is verified, replace part. While pushing down on seal, at stud end, if corrosion present at contact point at base of stud, replace part. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Tie Rod End Inspection Procedures > Page 7200 For All Other Vehicles Covered In This Article: Using a wrench, rotate the tie rod end so that the front of the seal on the outer tie rod end is expanded (Figure 1). Using a puffy knife or other hard, flat, dull object, lift the bottom of the seal up, exposing the stud (Figure 2). If any water escapes from the seal in the form of bubbles or in a liquid form, that tie rod end should be replaced. Closely examine the stud for signs of corrosion, especially around the interface with the knuckle. A rag might be needed to clean off any grease on the stud that impairs a good visual inspection. If there is any sign of corrosion, that tie rod end should be replaced. Rotate the tie rod end in the opposite direction to expand the inner tie rod seal. Repeat the inspection procedure used on the outer tie rod. Repeat this entire procedure on the other side of the vehicle. If there is sign of corrosion, that tie rod end should be replaced. NOTE IF ANY TIE ROD ENDS ARE REMOVED, INSPECT THE SEAL AND THE STUD AGAIN NOTING ANY DIFFERENCES IN VISUAL PERCEPTIONS FROM WHEN THE PART WAS ON THE VEHICLE. CHECKING THE STUD AFTER REMOVAL HELPS IMPROVE CONSCIOUSNESS OF ISSUES WHEN INSPECTING PARTS ON VEHICLE. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-9 WARRANTY STATUS: INFORMATION ONLY Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Tie Rod End Inspection Procedures > Page 7201 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Page 7202 Tie Rod End: Specifications Tie Rod End Castle Nut ....................................................................................................................... ........................................ 77-103 Nm (57-76 ft. lbs.) Toe Set Jam Nut ............................................... ........................................................................................................................................ 90 Nm (66 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner Tie Rod End: Service and Repair Inner Removal and Installation 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Remove the wheel and tire assembly. 2. Mark a reference point from the tie-rod end to the front wheel spindle tie-rod adjusting sleeve. 3. Loosen the toe set jam nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 7205 4. Remove the inner tie-rod end castellated nut. 1. Remove the cotter pin. 2. Remove the castellated nut. 5. On 4x2 vehicles, use the special tool to separate the tie-rod end. 6. On 4x4 vehicles, use the Separator to separate the tie-rod end. 7. Remove the tie-rod end. - Count and record rotations. 8. To install, reverse the removal procedure. 9. Inspect and adjust the toe adjustment. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 7206 Tie Rod End: Service and Repair Outer Special Tool(s) Removal and Installation 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Remove the wheel and tire assembly. 2. Mark a reference point from the tie-rod end to the front wheel spindle tie-rod adjusting sleeve. 3. Loosen the toe set jam nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 7207 4. Remove the outer tie-rod castellated nut. 1. Remove the cotter pin. 2. Remove the castellated nut. 5. Use the special tool to separate the tie-rod end. 6. Remove the tie-rod end. - Count and record the rotations. 7. To install, reverse the removal procedure. 8. Inspect and adjust the toe adjustment. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid Ball Joint: Specifications Front Suspension Balljoint Inspection Job Aid Front Lower Ball Joint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.032 in (0-0.8mm) Reference Diagram ............................................................................................................................. ............................................................................. A Front Upper Ball Joint Measurement .................................................................................................................................................. Between upper control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 7213 Reference Diagram ............................................................................................................................. ............................................................................. C Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 7214 Ball Joint: Specifications Ball Joint, Lower Lower Ball Joint Radial Play (Maximum) ............................................................................................................................................... 0.794 mm (1/32 in) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 7215 Ball Joint: Specifications Ball Joint, Upper Ball Joint Radial Play (Maximum) .......................................................................................................................................................... 0.794 mm (1/32 in) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid Ball Joint: Testing and Inspection Front Suspension Balljoint Inspection Job Aid Front Lower Ball Joint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.032 in (0-0.8mm) Reference Diagram ............................................................................................................................. ............................................................................. A Front Upper Ball Joint Measurement .................................................................................................................................................. Between upper control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid > Page 7218 Reference Diagram ............................................................................................................................. ............................................................................. C Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid > Page 7219 Ball Joint: Testing and Inspection Ball Joint, Lower WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Note: Prior to performing any inspection on 4x2 vehicles of the front suspension lower arm ball joints or front suspension upper ball joints, adjust the front wheel bearings. Note: Refer to the illustration for Steps 1 and 2. 1. Raise the vehicle and place safety stands under the suspension arm axle beneath the spring. 2. Have an assistant grasp the lower and upper edge of the tire and move the wheel in and out. 3. While the wheel is being moved, observe the lower spindle arm and the lower part of the axle jaw. A 0.794 mm (1/32 inch) or greater movement between the lower portion of the suspension arm and the lower spindle arm indicates that the front suspension lower arm ball joint must be replaced. 4. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Road test the vehicle for normal operation. To check the front suspension upper ball joints, grasp the upper edge of the tire and move the wheel in and out. A 0.794 mm (1/32 inch) or greater movement between the upper spindle arm and the upper portion of the suspension arm indicates that the front suspension upper ball joint must be replaced. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Balljoint Inspection Job Aid > Page 7220 Ball Joint: Testing and Inspection Ball Joint, Upper WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Note: Prior to performing any inspection on 4x2 vehicles of the front suspension lower arm ball joints or front suspension upper ball joints, adjust the front wheel bearings. Note: Refer to the illustration for Steps 1 and 2. 1. Raise the vehicle and place safety stands under the suspension arm axle beneath the spring. 2. Have an assistant grasp the lower and upper edge of the tire and move the wheel in and out. 3. While the wheel is being moved, observe the lower spindle arm and the lower part of the axle jaw. A 0.794 mm (1/32 inch) or greater movement between the lower portion of the suspension arm and the lower spindle arm indicates that the front suspension lower arm ball joint must be replaced. 4. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Road test the vehicle for normal operation. To check the front suspension upper ball joints, grasp the upper edge of the tire and move the wheel in and out. A 0.794 mm (1/32 inch) or greater movement between the upper spindle arm and the upper portion of the suspension arm indicates that the front suspension upper ball joint must be replaced. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 7221 Ball Joint: Service and Repair Ball Joint Removal and Installation Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the wheel and tire assembly. 3. Carry out the following: 1. Remove and discard the cotter pin. 2. Remove the retainer. 3. Remove the nut. 4.CAUTION:Do not allow the disc brake caliper to hang suspended from the brake hose. Provide a suitable support. Remove the caliper support bracket bolts, then position the caliper support bracket and caliper aside. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 7222 5. Remove the brake disc. 6. Disconnect the front anti-lock brake sensor (ABS) wire assembly. - Disconnect the ABS electrical connector. - Unclip the ABS harness routing clips. 7. Remove the tie-rod castellated nut. 1. Remove and discard the cotter pin. 2. Remove and discard the castellated nut. 8. CAUTION: Do not use a hammer to separate the tie-rod from the wheel knuckle or damage to the wheel knuckle will result. CAUTION: Do not damage the tie-rod boot when installing the special tool. Using the special tool, separate the tie-rod end from the front wheel knuckle. 9. Using a suitable jack, support the front suspension lower arm. 10. Remove the lower ball joint castellated nut. 1. Remove and discard the coffer pin. 2. Remove and discard the castellated nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 7223 11. Using the special tool, separate the front wheel knuckle from the suspension lower arm. Then, loosely install the castellated nut. 12. Remove the upper ball joint castellated nut. 1. Remove and discard the cotter pin. 2. Remove and discard the castellated nut. 13. Using the special tool, separate the front wheel knuckle from the front suspension upper arm. 14. Separate the halfshaft from the hub, then remove the hand-tightened lower ball joint castellated nut. Remove the front wheel knuckle. - Position the halfshaft aside and support with wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 7224 15. Remove the snap ring from the ball joint. Discard the snap ring 16. Using a suitable ball joint remover tool and receiver cup, remove the ball joint. CAUTION: Do not damage the ball joint boot when installing the special tool. NOTE: Clean and inspect the control arm ball joint bore for damage before installing a new ball joint. NOTE: Make sure the new ball joint snap ring is fully seated. 17. To install, reverse the removal procedure. - Always install new castellated nuts and coffer pins. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Specifications Control Arm: Specifications Front Brake Anti-Lock Sensor Bolt ................................................................................................................................................ 7-9 Nm (62-80 inch lbs.) Front Brake Anti-Lock Sensor Wire Bracket Bolt .......................................................................................................................... 7-9 Nm (62-80 inch lbs.) Brake Disc Shield Bolts .............................................................................................................................................................. 9-12 Nm (80-106 inch lbs.) Front Shock Absorber Lower Bolt And Nut ................................................................................................................................ 88-118 Nm (65-87 ft. lbs.) Front Shock Absorber Upper Nut .................................................................................................................................................. 30-40 Nm (22-29 ft. lbs.) Front Stabilizer Bar Link Bolt And Nut ......................................................................................................................................... 21-29 Nm (16-21 ft. lbs.) Front Suspension Lower Arm Nuts ........................................................................................................................................ 164-200 Nm (121-147 ft. lbs.) Front Suspension Lower Ball Joint Castle Nut ........................................................................................................................ 113-153 Nm (83-112 ft. lbs.) Front Suspension Upper Arm Ball Joint Castle Nut ..................................................................................................................... 77-103 Nm (57-76 ft. lbs.) Front Suspension Upper Arm Nuts .......................................................................................................................................... 113-153 Nm (83-113 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower Control Arm: Service and Repair Lower Removal 1. Remove the wheel hub. 2. Make preliminary adjustment references. 1. Make an alignment mark on the torsion bar and the torsion bar crossmember support. 2. Measure and record the length. 3. Relieve the torsion bar tension. 1. Remove the torsion bar adjuster bolt. 2. Install the Torsion Bar Tool with the Torsion Bar Tool Adapters in the B slots on the Torsion Bar Tool. 3. Tighten the Torsion Bar Tool until the torsion bar adjuster lifts off of the adjuster nut. 4. Remove the torsion bar adjuster nut. 5. Remove the Torsion Bar Tool. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7230 6. Remove the torsion bar adjuster. 4. Remove the stabilizer bar link nut from the front suspension lower arm. 5. Remove the front shock absorber lower bolt and nut from the front suspension lower arm. 6. Remove the lower ball joint castle nut. 1. Remove and discard the cotter pin. 2. Remove the lower ball joint castle nut. 7. Using the Pitman Arm Puller, separate the front suspension lower arm from the front wheel knuckle. - Separate the front suspension lower arm from the front wheel knuckle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7231 8. Remove the front suspension lower arm. 1. Remove the two front suspension lower arm nuts. 2. Remove the two front suspension lower arm bolts. 3. Remove the front suspension lower arm and torsion bar as an assembly. 9. Separate the front suspension lower arm from the torsion bar. Installation 1. Install the front suspension lower arm. 1. Attach the front suspension lower arm to the torsion bar. 2. Install the front suspension lower arm and torsion bar as an assembly. 3. Install the front suspension lower arm bolts and nuts. 2. Install the front suspension arm lower ball joint castle nut. 1. Position the front wheel knuckle. 2. Install the front suspension arm lower ball joint castle nut. 3. Install a new cotter pin. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7232 3. Install the front stabilizer bar link to the front suspension lower arm. 4. Install the front shock absorber lower bolt and nut to the front suspension lower arm. 5. Load the torsion bar. 1. Install the torsion bar adjuster. - Turn the torsion bar adjuster until the reference marks align. 2. Install the Torsion Bar Tool with the Torsion Bar Tool Adapters in the B slots on the Torsion Bar Tool. 3. Tighten the Torsion Bar Tool to load the torsion bar. 4. Install the torsion bar adjuster nut. 5. Install the torsion bar adjuster bolt. 6. Remove Torsion Bar Tool. 6. Install the wheel hub. 7. Adjust the ride height. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7233 Control Arm: Service and Repair Upper Special Tool(s) Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and wheel hearings. Remove the wheel and tire assembly. 3. Support the front suspension lower arm. - Position a jack under the front suspension lower arm. 4. Mark the position of the camber adjustment cam. 5. Safely reposition the anti-lock sensor wire. 1. Remove the bolt. 2. Safely reposition the anti- lock sensor wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7234 6. Remove the upper ball joint castle nut. 1. Remove and discard the cotter pin. 2. Remove the upper ball joint castle nut. 7. Use the Pitman Arm Puller to separate the front suspension upper arm from the front wheel knuckle. 8. Note: Mark the position of the camber adjustment cam. Remove the front suspension upper arm. 1. Remove the front suspension upper arm nuts. 2. Remove the front suspension upper arm pivot bolts. 3. Remove the front suspension upper arm. Installation 1. Note: Align the marks made during removal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7235 Install the front suspension upper arm. 1. Position the front suspension upper arm. 2. Install the front suspension upper arm bolts. 3. Install the front suspension upper arm nuts. 2. Install the front suspension arm upper ball joint castle nut. 1. Position the front wheel knuckle. 2. Install the upper ball joint castle nut. 3. Install a new cotter pin. 3. Position the anti-lock sensor wire. - Install the front brake anti-lock sensor wire bracket bolt. 4. Remove the jack. 5. WARNING: When the wheel is installed, always remove any corrosion, dirt or foreign material that may be present on the mounting surfaces of the wheels or the surfaces of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can cause the wheel nut to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. WARNING: Retighten at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened. - Failure to retighten wheel nuts at the mileage specified could allow wheels to come off while the vehicle is in motion, possibly causing loss of vehicle control and collision. Install the tire and wheel assembly. 6. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Lower > Page 7236 Lower the vehicle. 7. Check the front end alignment. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications Lateral Stabilizer Rod: Specifications Trackbar-To-Rear Axle Bolt .................................................................................................................................................. 170-230 Nm (125-170 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 7240 Lateral Stabilizer Rod: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Note: The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. Remove the air suspension height sensor, if so equipped. 1. Disconnect the electrical connector. 2. Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. 3. Remove the RH trackbar bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 7241 4. Remove the LH trackbar nut and bolt. 5. Remove the trackbar from the vehicle. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair Rear Knuckle: Service and Repair KNUCKLE Removal 1. Remove the wheel hub. 2. Make preliminary adjustment references. 1. Make an alignment mark on the torsion bar and the torsion bar crossmember support. 2. Measure and record the length. 3. Relieve the torsion bar tension. 1. Remove the torsion bar adjuster bolt. 2. Install the Torsion Bar Tool with the Torsion Bar Tool Adapters in the B slots on the Torsion Bar Tool. 3. Tighten the Torsion Bar Tool until the torsion bar adjuster lifts off of the adjuster nut. 4. Remove the torsion bar adjuster nut. 5. Remove the Torsion Bar Tool. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 7245 6. Remove the torsion bar adjuster. 4. Safely reposition the anti-lock sensor wire. 1. Remove the bolt. 2. Safely reposition the anti-lock sensor wire. 5. Remove the tie rod end castle nut. 1. Remove and discard the cotter pin. 2. Remove the tic rod end castle nut. 6. Using the Pitman Arm Puller, separate the tie rod end. - Separate the tie rod end from the front wheel knuckle. 7. Remove the front shock absorber lower bolt and nut from the front suspension lower arm. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 7246 8. Remove the upper ball joint castle nut. 1. Remove and discard the cotter pin. 2. Remove the upper ball joint castle nut. 9. Using the Pitman Arm Puller to separate the front wheel knuckle from the front suspension upper arm. 10. Remove the lower ball joint castle nut. 1. Remove and discard the cotter pin. 2. Remove the lower ball joint castle nut. 11. Using the Pitman Arm Puller to separate the front suspension lower arm from the front wheel knuckle. 12. CAUTION: Do not allow the front wheel driveshaft and joint to hang unsupported. Suspend the front wheel driveshaft and joint with wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 7247 Remove the front wheel knuckle. Installation 1. Install the front suspension arm lower ball joint castle nut. 1. Position the front wheel knuckle. 2. Install the front suspension arm lower ball joint castle nut. 3. Install a new cotter pin. 2. Install the front suspension arm upper ball joint castle nut. 1. Position the front wheel knuckle. 2. Install the front suspension arm upper ball joint castle nut. 3. Install a new cotter pin. 3. Install the front shock absorber lower bolt and nut to the front suspension lower arm. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 7248 4. Install the tie rod end castle nut. 1. Position the tie rod end. 2. Install the tie rod end castle nut. 3. Install a new cotter pin. 5. Position the anti-lock sensor wire. - Install the front brake anti-lock sensor wire bracket bolt. 6. Load the torsion bar. 1. Install the torsion bar adjuster. - Turn the torsion bar adjuster until the reference marks align. 2. Install the Torsion Bar Tool with the Torsion Bar Tool Adapters in the B slots on the Torsion Bar Tool. 3. Tighten the Torsion Bar Tool to load the torsion bar. 4. Install the torsion bar adjuster nut. 5. Install the torsion bar adjuster bolt. 6. Remove the Torsion Bar Tool. 7. Install the wheel hub. 8. Adjust the ride height. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7261 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7262 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > Component Information > Service and Repair Voltage Regulator: Service and Repair NOTE: The generator brush and terminal holder and the voltage regulator are installed as an assembly only. 1. Remove the generator, refer to Generator. 2. Remove the generator brush and terminal holder and the voltage regulator assembly. 1 Remove the screws. 2 Remove the generator brush and terminal holder and voltage regulator assembly. INSTALLATION 1. Install the generator brush and terminal holder and the voltage regulator assembly. 1 Depress the brushes and insert a wire to hold brushes during installation. 2 Install the generator brush and terminal holder and the voltage regulator assembly. 3 Install the screws and remove the wire. 2. Remove the generator, refer to Generator. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Control Module: > 01-4-2 > Mar > 01 > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Control Module: > 01-4-2 > Mar > 01 > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension Lamp ON/DTC's B2140 or C2140 Set > Page 7274 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Control Module: > 01-4-2 > Mar > 01 > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension Lamp ON/DTC's B2140 or C2140 Set > Page 7275 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Component Information > Specifications Brake Fluid: Specifications Brake Fluid High Performance DOT 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Component Information > Service and Repair Valve Body: Service and Repair Removal Note: If the transmission has been disassembled to replace worn or damaged parts, and the valves in the main control valve body stick repeatedly from foreign material, the torque converter must be removed and cleaned by using a mechanically agitated cleaner, such as the Torque Converter/Oil Cooler Cleaner. 1. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If this concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis. The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this is a temporary condition and will eventually return to normal operating condition. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the solenoid body electrical connector. 4. Remove the fluid pan gasket and filter. 5. Remove the accumulator body. 1 Remove the bolts. 2 Remove the nuts. 3 Remove the accumulator body. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Component Information > Service and Repair > Page 7281 6. CAUTION: Prevent the front of the valve body separator plate from sagging and displacing the check balls. If the valve body separator plate is not being serviced: 1 Remove the bolt. 2 Install the bolt into any case-threaded bolt hole on the opposite end of the separator plate. 7. Remove the main control valve body assembly. 1 Remove the bolts. 2 Remove the nuts. 3 Remove the main control valve body. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Component Information > Service and Repair > Page 7282 8. Remove the solenoid body assembly. 1 Remove the bolts. 2 Remove the nut. 3 Remove the solenoid body assembly. 9. Remove the solenoid screen assembly by rotating and pulling. 10. CAUTION: The steel Electronic Pressure Control (EPC) check ball is spring-loaded under the valve body separator plate. Note: If the valve body separator plates are not to be serviced, proceed to installation procedure. Remove the valve body separator plate reinforcement. 1 Remove the bolts. 2 Remove the separator plate reinforcement. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Component Information > Service and Repair > Page 7283 11. Lower and remove the valve body separator plate and gaskets. - The rubber check balls and the steel EPC check ball and spring assembly will fall out and may become lost or stick to the worm trail of the case. - Remove and discard separator plate gaskets. Installation CAUTION: Using the incorrect gaskets can cause damage to the transmission. 1. Note: Refer to parts catalog for proper gasket usage. Note: If the valve body separator plate was not removed, proceed to Step 6. Note: Apply a light film of petroleum jelly to the valve body separator plate prior to assembling the new gaskets. Assemble the new gaskets to the valve body separator plate. 1 Main control to case gasket. 2 Valve body separator plate. 3 Main control to separator plate gasket. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Component Information > Service and Repair > Page 7284 2. Note: Apply a small amount of petroleum jelly to each check ball prior to positioning them on the valve body separator plate. Install eight rubber and one steel EPC check balls. 3. Note: Apply petroleum jelly to the EPC check ball spring prior to installing it into the case. Install the EPC check ball spring. 4. Position the valve body separator plate and the gaskets to the case carefully to retain the check balls. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Component Information > Service and Repair > Page 7285 5. Note: The word "UP" stamped on the separator plate reinforcement, must be visible when installed. Install the separator plate reinforcement plate. 1 Position the separator plate reinforcement plate. 2 Install the bolts. 6. Install the solenoid screen assembly by pushing it in and rotating it to lock. 7. Note: Prior to installing the solenoid body assembly, coat the case connector bore with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A. Install the solenoid body assembly. 1 Install the solenoid body assembly. 2 Install the nut. 3 Install the bolts and nut finger-tight. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Component Information > Service and Repair > Page 7286 8. Install the main control valve body. 1 Install the main control valve body. 2 Aligning the manual shift valve with the manual valve detent lever. 3 Install the nuts finger-tight. 4 Install the bolts finger-tight. 9. If previously installed, remove, then reinstall the bolt into the separator plate reinforcing plate. 1 Remove the bolt. 2 Install the bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Component Information > Service and Repair > Page 7287 10. Install the accumulator body. 1 Install the accumulator body. 2 Install the nuts finger-tight. 3 Install the bolts finger-tight. 11. Tighten all the accumulator body, main control valve body, and solenoid body nuts and bolts. Tighten the bolts working from the center to the outside. 12. Install the fluid pan gasket and filter. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Component Information > Service and Repair > Page 7288 13. Connect the solenoid body electrical connector. 14. Lower the vehicle. 15. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Component Information > Specifications Transfer Case Actuator: Specifications Shift Motor Bolts .................................................................................................................................. ................................................. 10 Nm (89 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Component Information > Specifications > Page 7291 Transfer Case Actuator: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the coil wire pin from the electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire pin. - Use proper electrical connector pin remover. 4. CAUTION: Note each sensor wire pin location for correct installation. Remove the front and rear output shaft speed sensor wire pins from the electrical connector. Use the proper electrical connector pin remover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Service and Repair > Component Information > Specifications > Page 7292 5. Remove the transfer case shift motor. 1 Remove the four bolts. 2 Remove the transfer case shift motor. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Front Height Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Front Height Sensor > Page 7298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Rear Ride Height Sensor: Service and Repair Rear Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Note: The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. Remove the air suspension height sensor. 1. Disconnect the electrical connector. 2. Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Rear > Page 7301 Ride Height Sensor: Service and Repair 4-Wheel System Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Note: The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. Remove the air suspension height sensor. 1. Disconnect the electrical connector. 2. Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications Suspension Mode Switch: Specifications Air Suspension Switch Bracket Mounting Bolt .................................................................................................................. 10.2-13.8 Nm (91-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair > Rear Only System Suspension Mode Switch: Service and Repair Rear Only System Removal 1. Disconnect the battery ground cable. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. 4. Disconnect the air suspension switch electrical connector. 5. Remove the air suspension switch bracket mounting bolt. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair > Rear Only System > Page 7310 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair > Rear Only System > Page 7311 Suspension Mode Switch: Service and Repair 4-Wheel System Removal 1. Disconnect the battery ground cable. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. 4. Disconnect the air suspension switch electrical connector. 5. Remove the air suspension switch bracket mounting bolt. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair > Rear Only System > Page 7312 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Specifications Stabilizer Bar: Specifications Front Stabilizer Bar Bracket Bolts ................................................................................................................................................. 26-34 Nm (19-25 ft. lbs.) Front Stabilizer Bar Link Bolt And Nut ......................................................................................................................................... 21-29 Nm (16-21 ft. lbs.) Rear Stabilizer Bar-To-Axle Bolt ................................................................................................................................................ 86-114 Nm (63-84 ft. lbs.) Rear Stabilizer Bar Link-To-Frame Bolt ...................................................................................................................................... 86-114 Nm (63-84 ft. lbs.) Rear Stabilizer Bar Link-To-Stabilizer Bar Nut ........................................................................................................................... 86-114 Nm (63-84 ft. lbs.) Rear Stabilizer Bar Retainer-To-Axle Bolt .................................................................................................................................... 55-75 Nm (43-57 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Stabilizer Bar: Service and Repair Front Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and wheel bearings. Remove the right front tire and wheel assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 7318 3. Remove the skid plate. 1. Remove the skid plate bolts. 2. Remove the skid plate. 4. Remove the front stabilizer bar links. 1. Remove the front stabilizer bar link nuts. 2. Remove the front stabilizer bar link bolts. 3. Remove the front stabilizer bar spacers. 5. Remove the stabilizer bar brackets. 1. Remove the stabilizer bar bracket bolts. 2. Remove the stabilizer bar brackets. 3. Remove the stabilizer bar insulators. 6. Note: Rotate the front stabilizer bar to remove. Remove the front stabilizer bar. Installation 1. WARNING: When the wheel is installed, always remove any corrosion, dirt or foreign material that may be present on the mounting surfaces of the wheels or the surfaces of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can cause the wheel nut to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 7319 To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 7320 Stabilizer Bar: Service and Repair Rear Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the stabilizer bar link nut. 3. Remove the stabilizer bar link bolt and the stabilizer bar link. 4. Remove the stabilizer bar from the rear axle. 1. Remove the stabilizer bar retainer bolts. 2. Remove the stabilizer bar retainers and the stabilizer bar. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 7321 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures Air Dryer: Technical Service Bulletins Air Suspension - Repeat Compressor Drier Failures Article No. 03-9-2 05/12/03 ^ SUSPENSION - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES ^ ELECTRICAL - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES FORD: 1997-2002 EXPEDITION LINCOLN: 1998-2002 NAVIGATOR Article 03-7-9 is being republished in its entirety to update the Service Procedure. ISSUE Some 1997-2002 Expedition 4X4 and 1998-2002 Navigator 4X4 vehicles equipped with 4-wheel air suspension, may exhibit repeat air compressor drier failures. The drier cap may become detached from the drier body, or the drier body may be broken at the neck near the compressor head. This may be due to incomplete or incorrect system diagnosis that leads to replacement of only the original air suspension compressor, despite the fact that the compressor is not the root cause of the concern. Compressor failure in these instances is only a symptom of an underlying system problem. ACTION Refer to the service information contained in this TSB for information on proper diagnosis of system issues. Be sure to check the system for proper pneumatic function as described during service to ensure a robust repair. SERVICE INFORMATION Overview Proper pneumatic function can be tested by verifying that both the front AND the rear of the vehicle can be raised and lowered one inch using a scan tool, and by monitoring the height sensor PIDs for movement while the vehicle is in the service bay. If the vehicle does not raise and lower normally, check the solenoid valves and air lines for blockages and/or restrictions. Replace any blocked or restricted solenoids and air lines. ALWAYS check for proper pneumatic function before returning the vehicle back to the customer. NOTE DISCONNECTING AN AIR LINE THAT IS CONNECTED TO THE AIR COMPRESSOR CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE IS VENTED UNCONTROLLED. If diagnostics lead to compressor/dryer assembly replacement, use the following service procedure to insure complete and thorough service. 1. Using the New Generation STAR (NGS) tester, vent the compressor/drier assembly. 2. Using regulated shop air, blow out the air lines from the drier to the front fill solenoid valve and from the drier to the rear fill solenoid valve, before installing the new compressor assembly. 3. Replace the air suspension compressor assembly. Refer to Workshop Manual Section 204-05 for compressor installation instructions. 4. Replace the front fill solenoid. Refer to Workshop Manual Section 204-05 for replacement instructions. The front fill solenoid must be replaced because in these cases, it may have sustained damage from the drier desiccant or other contaminants. 5. Connect the New Generation STAR (NGS) tester to the vehicle while the vehicle is parked in the service bay with the engine running. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 7327 6. Install a pressure gauge capable of reading 400 PSI at the front air line (Figure 1). Using the scan tool, command the compressor ON. Check the output of the compressor on the gauge: a. If the compressor does not output at least 110 PSI within 30 seconds, replace the compressor again and retest. NOTE VERIFY THAT THE SUSPENSION RAISES PROPERLY. 7. Using the scan tool, command the front of the vehicle to raise up one inch. The front suspension should rise one inch in 25 seconds or less. a. If the compressor output is near 300 PSI, check4or air line or solenoid restrictions, repair as necessary and retest. Otherwise, proceed to Step 7b. NOTE SUSPENSION UPWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD DECREASE BY .35 TO .45 VOLTS. b. If the front of the vehicle DOES NOT raise, check the front pneumatic system for leaks, inoperable or blocked solenoid valves or pinched air lines. If an issue is found, repair as required and repeat Step 7 to verify proper operation. c. If no problem found, continue to Step 8. NOTE VERIFY THAT SUSPENSION PROPERLY. 8. If the front of the vehicle DOES raise, use the scan tool to command the front of the vehicle to lower one inch. The front suspension should lower one inch in 20 seconds or less. NOTE SUSPENSION DOWNWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD INCREASE BY .35 TO .45 VOLTS. a. If the front of the vehicle DOES NOT lower, check the front pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines. Repair air lines or replace solenoid valves as required. 9. Repeat Steps 7 and 8 for the rear. Command the rear of the vehicle, and monitor the rear height sensor PID. Voltages should increase when the vehicle is lowered, and decrease when the vehicle is raised. If the rear of the vehicle does not raise and lower as commanded, inspect the rear pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines, and repair as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 7328 10. If the vehicle raises and lowers normally in both the front and the rear, test drive the vehicle to confirm the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-7-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 304000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Technical Service Bulletins > Page 7329 Air Dryer: Specifications Compressor Air Drier Hold Down Screw ....................................................................................................................................... 2-3 Nm (18-27 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Service and Repair > Rear Only System Air Dryer: Service and Repair Rear Only System Removal 1. Remove the air compressor. 2. Remove the air compressor drier. 1. Remove the screw. 2. Rotate 90° to unlock then remove the air compressor drier. Installation 1. Note: Inspect the 0-ring for damage and replace as necessary. Lubricate the solenoid seal area with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331A or equivalent meeting Ford specification ESE-M1C171-A. Note: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. - Ride height adjustments must be performed after the air compressor/drier is installed. - When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Service and Repair > Rear Only System > Page 7332 Air Dryer: Service and Repair 4-Wheel System Removal 1. Remove the air compressor. 2. Remove the air compressor drier. 1. Remove the screw. 2. Rotate 90° to unlock then remove the air compressor drier. Installation 1. Note: Inspect the O-ring for damage and replace as necessary. Lubricate the solenoid seal area with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331A or equivalent meeting Ford specification ESE-M1C171-A. Note: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. - Ride height adjustments must be performed after the air compressor/drier is installed. - When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures Air Line: Technical Service Bulletins Air Suspension - Repeat Compressor Drier Failures Article No. 03-9-2 05/12/03 ^ SUSPENSION - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES ^ ELECTRICAL - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES FORD: 1997-2002 EXPEDITION LINCOLN: 1998-2002 NAVIGATOR Article 03-7-9 is being republished in its entirety to update the Service Procedure. ISSUE Some 1997-2002 Expedition 4X4 and 1998-2002 Navigator 4X4 vehicles equipped with 4-wheel air suspension, may exhibit repeat air compressor drier failures. The drier cap may become detached from the drier body, or the drier body may be broken at the neck near the compressor head. This may be due to incomplete or incorrect system diagnosis that leads to replacement of only the original air suspension compressor, despite the fact that the compressor is not the root cause of the concern. Compressor failure in these instances is only a symptom of an underlying system problem. ACTION Refer to the service information contained in this TSB for information on proper diagnosis of system issues. Be sure to check the system for proper pneumatic function as described during service to ensure a robust repair. SERVICE INFORMATION Overview Proper pneumatic function can be tested by verifying that both the front AND the rear of the vehicle can be raised and lowered one inch using a scan tool, and by monitoring the height sensor PIDs for movement while the vehicle is in the service bay. If the vehicle does not raise and lower normally, check the solenoid valves and air lines for blockages and/or restrictions. Replace any blocked or restricted solenoids and air lines. ALWAYS check for proper pneumatic function before returning the vehicle back to the customer. NOTE DISCONNECTING AN AIR LINE THAT IS CONNECTED TO THE AIR COMPRESSOR CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE IS VENTED UNCONTROLLED. If diagnostics lead to compressor/dryer assembly replacement, use the following service procedure to insure complete and thorough service. 1. Using the New Generation STAR (NGS) tester, vent the compressor/drier assembly. 2. Using regulated shop air, blow out the air lines from the drier to the front fill solenoid valve and from the drier to the rear fill solenoid valve, before installing the new compressor assembly. 3. Replace the air suspension compressor assembly. Refer to Workshop Manual Section 204-05 for compressor installation instructions. 4. Replace the front fill solenoid. Refer to Workshop Manual Section 204-05 for replacement instructions. The front fill solenoid must be replaced because in these cases, it may have sustained damage from the drier desiccant or other contaminants. 5. Connect the New Generation STAR (NGS) tester to the vehicle while the vehicle is parked in the service bay with the engine running. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 7337 6. Install a pressure gauge capable of reading 400 PSI at the front air line (Figure 1). Using the scan tool, command the compressor ON. Check the output of the compressor on the gauge: a. If the compressor does not output at least 110 PSI within 30 seconds, replace the compressor again and retest. NOTE VERIFY THAT THE SUSPENSION RAISES PROPERLY. 7. Using the scan tool, command the front of the vehicle to raise up one inch. The front suspension should rise one inch in 25 seconds or less. a. If the compressor output is near 300 PSI, check4or air line or solenoid restrictions, repair as necessary and retest. Otherwise, proceed to Step 7b. NOTE SUSPENSION UPWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD DECREASE BY .35 TO .45 VOLTS. b. If the front of the vehicle DOES NOT raise, check the front pneumatic system for leaks, inoperable or blocked solenoid valves or pinched air lines. If an issue is found, repair as required and repeat Step 7 to verify proper operation. c. If no problem found, continue to Step 8. NOTE VERIFY THAT SUSPENSION PROPERLY. 8. If the front of the vehicle DOES raise, use the scan tool to command the front of the vehicle to lower one inch. The front suspension should lower one inch in 20 seconds or less. NOTE SUSPENSION DOWNWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD INCREASE BY .35 TO .45 VOLTS. a. If the front of the vehicle DOES NOT lower, check the front pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines. Repair air lines or replace solenoid valves as required. 9. Repeat Steps 7 and 8 for the rear. Command the rear of the vehicle, and monitor the rear height sensor PID. Voltages should increase when the vehicle is lowered, and decrease when the vehicle is raised. If the rear of the vehicle does not raise and lower as commanded, inspect the rear pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines, and repair as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 7338 10. If the vehicle raises and lowers normally in both the front and the rear, test drive the vehicle to confirm the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-7-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 304000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Service and Repair > Air Line Fluid Purge Air Line: Service and Repair Air Line Fluid Purge Rear Only System 1. Note: Perform this procedure if fluid (water or oil) is found in the rear air lines. Purge fluid from air lines and replace affected components. Disconnect the air line at the compressor air drier. 2. Disconnect the rear LH and RH air lines from the air springs. 3. Connect the shop air line to any disconnected air line and blow any fluid out. 4. Note: When installing the air lines make sure the white air line is fully inserted into the fitting for correct installation. Reconnect the air lines at the RH and LH air springs. 5. Replace the compressor air drier. 6. Note: When installing the air lines make sure the white air line is fully inserted into the fitting for correct installation. Reconnect the air line at the compressor air drier. 7. Make sure all air line fittings are scaled. Front 1. Note: If oil is present in the air lines, replace both LF and RF air shocks. Do not replace air shocks if only water is found in the air lines. Disconnect the air line at the air compressor drier that is connected to the front fill solenoid inlet. 2. Disconnect the air line at the RF shock. 3. Connect scan tool to the Data Link Connector (DLC). 4. Turn the 4WAS FRNT - FILL (front fill solenoid) solenoid ON. 5. Connect shop air line to the disconnected air line and blow out any fluid. 6. Note: When installing air lines, make sure the white air line is fully inserted into the fitting for correct installation. Reconnect the air line at the RF air shock. 7. Disconnect the air line at the LF air shock. 8. Turn on the following 4WAS solenoid: - FRNT-FILL (front fill solenoid) ON. - GATEVALVE (front gate solenoid) ON. 9. Connect the shop air line to the disconnected air line and blow out any fluid. 10. Note: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. Reconnect the air line at the LF air shock. 11. Replace the air compressor drier. 12. Note: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. Reconnect the air line to the air compressor drier. Rear 1. Disconnect the air line at the air compressor drier that is connected to the rear fill solenoid inlet. 2. Disconnect the air lines at the rear LH and RH air spring solenoids. 3. Connect scan tool to the vehicle. 4. Turn the 4WAS - REAR-FILL (rear fill solenoid) solenoid ON. 5. Connect the shop air line to the disconnected air line and blow out any fluid. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Service and Repair > Air Line Fluid Purge > Page 7341 6. Note: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. Reconnect the air line at the rear LH and RH air spring solenoids. 7. Replace the air compressor drier. 8. Note: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. Reconnect the air line to the air compressor drier. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Line, Suspension Control > Component Information > Service and Repair > Air Line Fluid Purge > Page 7342 Air Line: Service and Repair Air Line Repair Rear Only System Note: A soapy water solution can be applied to the air lines to verify the location of air leaks. 1. if a leak is detected in an air line, it can be repaired by carefully making a good, clean, straight cut. Trim back the outer covering of the air line 16-20 mm (0.63-0.78 inch) to reveal the white inner line. Install a repair fitting and wrap securely with electrical tape. 2. If multiple leaks are detected, replace the entire air line. 4-Wheel System Note: A soapy water solution can be applied to the air lines to verify the location of air leaks. 1. If a leak is detected in an air line, it can be repaired by carefully making a good, clean, straight cut. Trim back the outer covering of the air line 16-20 mm (0.63-0.78 inch) to reveal the white inner line. Install a repair fitting and wrap securely with electrical tape. 2. If multiple leaks are detected, replace the entire air line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Fill-Refold Procedure Air Spring: Service and Repair Air Spring Fill-Refold Procedure Rear Only System WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. CAUTION: Do not clamp any portion of the air spring piston. 1. Place air spring on flat surface. 2. Remove air spring solenoid to expand collapsed air bag. 3. Push membrane down over piston to correct height. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Fill-Refold Procedure > Page 7347 4. Install air spring solenoid to help maintain correct height. 4-Wheel System WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. CAUTION: Do not clamp any portion of the air spring piston. 1. Place air spring on flat surface. 2. Remove air spring solenoid to expand collapsed air bag. 3. Push membrane down over piston to correct height. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Fill-Refold Procedure > Page 7348 4. Install air spring solenoid to help maintain correct height. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Fill-Refold Procedure > Page 7349 Air Spring: Service and Repair Removal and Installation Rear Only System Removal WARNING: Before repairing or installing any air suspension component(s), turn off the air suspension switch or disconnect the battery ground cable to prevent vehicle damage or personal injury. - Do not attempt to install or inflate any air spring that has become unfolded to prevent vehicle damage or personal injury. - Failure to observe the following procedures may result in a sudden failure of the suspension system. - Any air spring which is unfolded must be refolded prior to being installed in a vehicle. - The air spring refolding procedure should not be used for an air spring which has never supported the vehicle's weight while in the correctly folded position. - Vehicles with an incorrectly folded air spring(s) found after the vehicle has been driven, must have a new air spring installed. - Do not attempt to inflate any air spring which has collapsed while deflated from the rebound hanging position to the jounce stop. - When installing a new air spring, care must be taken to not apply a load to the suspension until the air springs have been inflated using the air spring fill procedure. - After inflating an air spring in the hanging position, it must be inspected for proper shape. Note: The vehicle must be positioned on a suitable lifting device prior to deflating the air suspension system. 1. Deflate the air suspension system. 2. Disconnect the battery ground cable. 3. Raise and support the vehicle. 4. Remove the rear air spring retainer. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Fill-Refold Procedure > Page 7350 5. Lift the bottom of the air spring off the rear axle. 6. Disconnect the-air line from the air spring. - Compress the quick connect locking ring and pull out the air line. 7. Disconnect the air spring solenoid electrical connector and remove the air spring. Installation 1. Note: When installing the rear air spring, it is necessary to inflate the air suspension system. Connect the solenoid valve electrical connector. 2. Note: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Fill-Refold Procedure > Page 7351 Connect the air line into the solenoid valve line fitting. 3. Position the air spring into place and install the retaining clip at the top of the air spring. 4. Visually inspect each air spring to ensure the correct profile has been obtained and the air spring is secured to the axle housing. There should be no evidence of buckling or folding of the air springs. 5. Lower the vehicle. 6. Inflate the air suspension system. Air Spring - Rear Removal Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Fill-Refold Procedure > Page 7352 WARNING: Before repairing or installing any air suspension component(s), turn off the air suspension switch or disconnect the battery ground cable to prevent vehicle damage or personal injury. - Do not attempt to install or inflate any air spring that has become unfolded to prevent vehicle damage or personal injury. - Failure to observe the following procedures may result in a sudden failure of the suspension system. - Any air spring which is unfolded must be refolded prior to being installed in a vehicle. - The air spring refolding procedure should not be used for an air spring which has never supported the vehicle's weight while in the correctly folded position. - Vehicles with an incorrectly folded air spring(s) found after the vehicle has been driven, must have a new air spring installed. - Do not attempt to inflate any air spring which has collapsed while deflated from the rebound hanging position to the jounce stop. - When installing a new air spring, care must be taken to not apply a load to the suspension until the air springs have been inflated using the air spring fill procedure. - After inflating an air spring in the hanging position, it must be inspected for proper shape. Note: The vehicle must be positioned on a suitable lifting device prior to deflating the air suspension system. 1. Deflate the air suspension system. 2. Disconnect the battery ground cable. 3. Raise and support the vehicle. 4. Remove the rear air spring retainer. 5. Lift the bottom of the air spring off the rear axle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Fill-Refold Procedure > Page 7353 6. Disconnect the air line from the air spring. - Compress the quick connect locking ring and pull out the air line. 7. Disconnect the air spring solenoid electrical connector and remove the air spring. Installation 1. Note: When installing the rear air spring, it is necessary to inflate the air suspension system. Connect the solenoid valve electrical connector. 2. Note: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. Connect the air line into the solenoid valve line fitting. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Spring > Component Information > Service and Repair > Air Spring Fill-Refold Procedure > Page 7354 3. Position the air spring into place and install the retaining clip at the top of the air spring. 4. Visually inspect each air spring to ensure the correct profile has been obtained and the air spring is secured to the axle housing. There should be no evidence of buckling or folding of the air springs. 5. Lower the vehicle. 6. Inflate the air suspension system. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Customer Interest: > 05-26-18 > Dec > 05 > Suspension - Air Suspension Excessive Compressor Noise Compressor/Pump: Customer Interest Suspension - Air Suspension Excessive Compressor Noise TSB 05-26-18 12/31/05 AIR SUSPENSION COMPRESSOR NOISE FORD: 1997-2004 Expedition LINCOLN: 1998-2004 Navigator This article supersedes TSB 04-5-4 to update the Service Procedure. ISSUE Some 1997-2004 Expedition and 1998-2004 Navigator vehicles equipped with air suspension, may exhibit excessive noise from the air suspension compressor. ACTION To service, replace the compressor mounting bracket with a revised bracket. Order and install Noise Kit 4L1Z-5Z205-AA. Refer to the instruction sheets included in the Kit for installation procedures. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052618A 1997-2004 1.0 Hr. Expedition/1998-2004 Navigator: Install Newly Designed Mounting Bracket And Isolators (Includes Time To Remove And Install Air Suspension Compressor) DEALER CODING CONDITION BASIC PART NO. CODE 5319 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 05-26-18 > Dec > 05 > Suspension - Air Suspension Excessive Compressor Noise Compressor/Pump: All Technical Service Bulletins Suspension - Air Suspension Excessive Compressor Noise TSB 05-26-18 12/31/05 AIR SUSPENSION COMPRESSOR NOISE FORD: 1997-2004 Expedition LINCOLN: 1998-2004 Navigator This article supersedes TSB 04-5-4 to update the Service Procedure. ISSUE Some 1997-2004 Expedition and 1998-2004 Navigator vehicles equipped with air suspension, may exhibit excessive noise from the air suspension compressor. ACTION To service, replace the compressor mounting bracket with a revised bracket. Order and install Noise Kit 4L1Z-5Z205-AA. Refer to the instruction sheets included in the Kit for installation procedures. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052618A 1997-2004 1.0 Hr. Expedition/1998-2004 Navigator: Install Newly Designed Mounting Bracket And Isolators (Includes Time To Remove And Install Air Suspension Compressor) DEALER CODING CONDITION BASIC PART NO. CODE 5319 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures Compressor/Pump: All Technical Service Bulletins Air Suspension - Repeat Compressor Drier Failures Article No. 03-9-2 05/12/03 ^ SUSPENSION - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES ^ ELECTRICAL - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES FORD: 1997-2002 EXPEDITION LINCOLN: 1998-2002 NAVIGATOR Article 03-7-9 is being republished in its entirety to update the Service Procedure. ISSUE Some 1997-2002 Expedition 4X4 and 1998-2002 Navigator 4X4 vehicles equipped with 4-wheel air suspension, may exhibit repeat air compressor drier failures. The drier cap may become detached from the drier body, or the drier body may be broken at the neck near the compressor head. This may be due to incomplete or incorrect system diagnosis that leads to replacement of only the original air suspension compressor, despite the fact that the compressor is not the root cause of the concern. Compressor failure in these instances is only a symptom of an underlying system problem. ACTION Refer to the service information contained in this TSB for information on proper diagnosis of system issues. Be sure to check the system for proper pneumatic function as described during service to ensure a robust repair. SERVICE INFORMATION Overview Proper pneumatic function can be tested by verifying that both the front AND the rear of the vehicle can be raised and lowered one inch using a scan tool, and by monitoring the height sensor PIDs for movement while the vehicle is in the service bay. If the vehicle does not raise and lower normally, check the solenoid valves and air lines for blockages and/or restrictions. Replace any blocked or restricted solenoids and air lines. ALWAYS check for proper pneumatic function before returning the vehicle back to the customer. NOTE DISCONNECTING AN AIR LINE THAT IS CONNECTED TO THE AIR COMPRESSOR CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE IS VENTED UNCONTROLLED. If diagnostics lead to compressor/dryer assembly replacement, use the following service procedure to insure complete and thorough service. 1. Using the New Generation STAR (NGS) tester, vent the compressor/drier assembly. 2. Using regulated shop air, blow out the air lines from the drier to the front fill solenoid valve and from the drier to the rear fill solenoid valve, before installing the new compressor assembly. 3. Replace the air suspension compressor assembly. Refer to Workshop Manual Section 204-05 for compressor installation instructions. 4. Replace the front fill solenoid. Refer to Workshop Manual Section 204-05 for replacement instructions. The front fill solenoid must be replaced because in these cases, it may have sustained damage from the drier desiccant or other contaminants. 5. Connect the New Generation STAR (NGS) tester to the vehicle while the vehicle is parked in the service bay with the engine running. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures > Page 7372 6. Install a pressure gauge capable of reading 400 PSI at the front air line (Figure 1). Using the scan tool, command the compressor ON. Check the output of the compressor on the gauge: a. If the compressor does not output at least 110 PSI within 30 seconds, replace the compressor again and retest. NOTE VERIFY THAT THE SUSPENSION RAISES PROPERLY. 7. Using the scan tool, command the front of the vehicle to raise up one inch. The front suspension should rise one inch in 25 seconds or less. a. If the compressor output is near 300 PSI, check4or air line or solenoid restrictions, repair as necessary and retest. Otherwise, proceed to Step 7b. NOTE SUSPENSION UPWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD DECREASE BY .35 TO .45 VOLTS. b. If the front of the vehicle DOES NOT raise, check the front pneumatic system for leaks, inoperable or blocked solenoid valves or pinched air lines. If an issue is found, repair as required and repeat Step 7 to verify proper operation. c. If no problem found, continue to Step 8. NOTE VERIFY THAT SUSPENSION PROPERLY. 8. If the front of the vehicle DOES raise, use the scan tool to command the front of the vehicle to lower one inch. The front suspension should lower one inch in 20 seconds or less. NOTE SUSPENSION DOWNWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD INCREASE BY .35 TO .45 VOLTS. a. If the front of the vehicle DOES NOT lower, check the front pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines. Repair air lines or replace solenoid valves as required. 9. Repeat Steps 7 and 8 for the rear. Command the rear of the vehicle, and monitor the rear height sensor PID. Voltages should increase when the vehicle is lowered, and decrease when the vehicle is raised. If the rear of the vehicle does not raise and lower as commanded, inspect the rear pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines, and repair as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures > Page 7373 10. If the vehicle raises and lowers normally in both the front and the rear, test drive the vehicle to confirm the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-7-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 304000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures Compressor/Pump: All Technical Service Bulletins Air Suspension - Repeat Compressor Drier Failures Article No. 03-9-2 05/12/03 ^ SUSPENSION - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES ^ ELECTRICAL - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES FORD: 1997-2002 EXPEDITION LINCOLN: 1998-2002 NAVIGATOR Article 03-7-9 is being republished in its entirety to update the Service Procedure. ISSUE Some 1997-2002 Expedition 4X4 and 1998-2002 Navigator 4X4 vehicles equipped with 4-wheel air suspension, may exhibit repeat air compressor drier failures. The drier cap may become detached from the drier body, or the drier body may be broken at the neck near the compressor head. This may be due to incomplete or incorrect system diagnosis that leads to replacement of only the original air suspension compressor, despite the fact that the compressor is not the root cause of the concern. Compressor failure in these instances is only a symptom of an underlying system problem. ACTION Refer to the service information contained in this TSB for information on proper diagnosis of system issues. Be sure to check the system for proper pneumatic function as described during service to ensure a robust repair. SERVICE INFORMATION Overview Proper pneumatic function can be tested by verifying that both the front AND the rear of the vehicle can be raised and lowered one inch using a scan tool, and by monitoring the height sensor PIDs for movement while the vehicle is in the service bay. If the vehicle does not raise and lower normally, check the solenoid valves and air lines for blockages and/or restrictions. Replace any blocked or restricted solenoids and air lines. ALWAYS check for proper pneumatic function before returning the vehicle back to the customer. NOTE DISCONNECTING AN AIR LINE THAT IS CONNECTED TO THE AIR COMPRESSOR CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE IS VENTED UNCONTROLLED. If diagnostics lead to compressor/dryer assembly replacement, use the following service procedure to insure complete and thorough service. 1. Using the New Generation STAR (NGS) tester, vent the compressor/drier assembly. 2. Using regulated shop air, blow out the air lines from the drier to the front fill solenoid valve and from the drier to the rear fill solenoid valve, before installing the new compressor assembly. 3. Replace the air suspension compressor assembly. Refer to Workshop Manual Section 204-05 for compressor installation instructions. 4. Replace the front fill solenoid. Refer to Workshop Manual Section 204-05 for replacement instructions. The front fill solenoid must be replaced because in these cases, it may have sustained damage from the drier desiccant or other contaminants. 5. Connect the New Generation STAR (NGS) tester to the vehicle while the vehicle is parked in the service bay with the engine running. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures > Page 7379 6. Install a pressure gauge capable of reading 400 PSI at the front air line (Figure 1). Using the scan tool, command the compressor ON. Check the output of the compressor on the gauge: a. If the compressor does not output at least 110 PSI within 30 seconds, replace the compressor again and retest. NOTE VERIFY THAT THE SUSPENSION RAISES PROPERLY. 7. Using the scan tool, command the front of the vehicle to raise up one inch. The front suspension should rise one inch in 25 seconds or less. a. If the compressor output is near 300 PSI, check4or air line or solenoid restrictions, repair as necessary and retest. Otherwise, proceed to Step 7b. NOTE SUSPENSION UPWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD DECREASE BY .35 TO .45 VOLTS. b. If the front of the vehicle DOES NOT raise, check the front pneumatic system for leaks, inoperable or blocked solenoid valves or pinched air lines. If an issue is found, repair as required and repeat Step 7 to verify proper operation. c. If no problem found, continue to Step 8. NOTE VERIFY THAT SUSPENSION PROPERLY. 8. If the front of the vehicle DOES raise, use the scan tool to command the front of the vehicle to lower one inch. The front suspension should lower one inch in 20 seconds or less. NOTE SUSPENSION DOWNWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD INCREASE BY .35 TO .45 VOLTS. a. If the front of the vehicle DOES NOT lower, check the front pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines. Repair air lines or replace solenoid valves as required. 9. Repeat Steps 7 and 8 for the rear. Command the rear of the vehicle, and monitor the rear height sensor PID. Voltages should increase when the vehicle is lowered, and decrease when the vehicle is raised. If the rear of the vehicle does not raise and lower as commanded, inspect the rear pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines, and repair as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for Compressor/Pump: > 03-9-2 > May > 03 > Air Suspension - Repeat Compressor Drier Failures > Page 7380 10. If the vehicle raises and lowers normally in both the front and the rear, test drive the vehicle to confirm the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-7-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 304000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Technical Service Bulletins > Page 7381 Compressor/Pump: Specifications Air Compressor Bracket Bolts ................................................................................................................................................ 7.6-10.4 Nm (68-88 inch lbs.) Compressor Air Drier Hold Down Screw ....................................................................................................................................... 2-3 Nm (18-27 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Service and Repair > Rear Only System Compressor/Pump: Service and Repair Rear Only System Removal 1. WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. WARNING: Disconnecting an airline that is connected to the air compressor can cause personal injury or damage to components as high pressure air is vented uncontrolled. Note: The vehicle must be positioned on a suitable lifting device prior to deflating the air suspension system. Deflate the air suspension system. 2. Disconnect the battery ground cable. 3. Remove the windshield washer pump and reservoir. 4. Disconnect the air lines from the air compressor. 1. Compress the quick connect locking rings and hold firmly while pulling out on the air lines. 2. Disconnect the air lines. 5. Disconnect the air compressor electrical connector. 6. Remove the air compressor bracket bolts and remove the air compressor and drier assembly. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Service and Repair > Rear Only System > Page 7384 1. Note: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. - After installing the air compressor it is necessary to inflate the air suspension system. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Service and Repair > Rear Only System > Page 7385 Compressor/Pump: Service and Repair 4-Wheel System Removal 1. WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. WARNING: Disconnecting an airline that is connected to the air compressor can cause personal injury or damage to components as high pressure air is vented uncontrolled. Note: The vehicle must be positioned on a suitable lifting device prior to deflating the air suspension system. Deflate the air suspension system. 2. Disconnect the battery ground cable. 3. Remove the windshield washer pump and reservoir. 4. Disconnect the air lines from the air compressor. 1. Compress the quick connect locking rings and hold firmly while pulling out on the air lines. 2. Disconnect the air lines. 5. Disconnect the air compressor electrical connector. 6. Remove the air compressor bracket bolts and remove the air compressor and drier assembly. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Service and Repair > Rear Only System > Page 7386 1. Note: - When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. - When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. - After installing the air compressor it is necessary to inflate the air suspension system. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Damping Control Actuator > Component Information > Service and Repair Damping Control Actuator: Service and Repair Removal Note: The vehicle must be positioned on a suitable lifting device prior to deflating the air suspension system. 1. Deflate the air suspension system. 2. Raise and support the vehicle. 3. On LH air shock removal only, disconnect the top of the front height sensor from the upper frame bracket. 4. Remove the air shock lower nut and bolt. 5. Disconnect the air spring solenoid air line. - Compress the quick connect locking ring and pull out the air line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Damping Control Actuator > Component Information > Service and Repair > Page 7393 6. Remove the air shock upper nut, grommet, and the air shock. Installation 1. Note: After installing the air shock, it is necessary to inflate the air suspension system. Note: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures Level Control Solenoid Valve: Technical Service Bulletins Air Suspension - Repeat Compressor Drier Failures Article No. 03-9-2 05/12/03 ^ SUSPENSION - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES ^ ELECTRICAL - REPEAT AIR SUSPENSION COMPRESSOR DRIER FAILURES FORD: 1997-2002 EXPEDITION LINCOLN: 1998-2002 NAVIGATOR Article 03-7-9 is being republished in its entirety to update the Service Procedure. ISSUE Some 1997-2002 Expedition 4X4 and 1998-2002 Navigator 4X4 vehicles equipped with 4-wheel air suspension, may exhibit repeat air compressor drier failures. The drier cap may become detached from the drier body, or the drier body may be broken at the neck near the compressor head. This may be due to incomplete or incorrect system diagnosis that leads to replacement of only the original air suspension compressor, despite the fact that the compressor is not the root cause of the concern. Compressor failure in these instances is only a symptom of an underlying system problem. ACTION Refer to the service information contained in this TSB for information on proper diagnosis of system issues. Be sure to check the system for proper pneumatic function as described during service to ensure a robust repair. SERVICE INFORMATION Overview Proper pneumatic function can be tested by verifying that both the front AND the rear of the vehicle can be raised and lowered one inch using a scan tool, and by monitoring the height sensor PIDs for movement while the vehicle is in the service bay. If the vehicle does not raise and lower normally, check the solenoid valves and air lines for blockages and/or restrictions. Replace any blocked or restricted solenoids and air lines. ALWAYS check for proper pneumatic function before returning the vehicle back to the customer. NOTE DISCONNECTING AN AIR LINE THAT IS CONNECTED TO THE AIR COMPRESSOR CAN CAUSE PERSONAL INJURY OR DAMAGE TO COMPONENTS AS HIGH PRESSURE IS VENTED UNCONTROLLED. If diagnostics lead to compressor/dryer assembly replacement, use the following service procedure to insure complete and thorough service. 1. Using the New Generation STAR (NGS) tester, vent the compressor/drier assembly. 2. Using regulated shop air, blow out the air lines from the drier to the front fill solenoid valve and from the drier to the rear fill solenoid valve, before installing the new compressor assembly. 3. Replace the air suspension compressor assembly. Refer to Workshop Manual Section 204-05 for compressor installation instructions. 4. Replace the front fill solenoid. Refer to Workshop Manual Section 204-05 for replacement instructions. The front fill solenoid must be replaced because in these cases, it may have sustained damage from the drier desiccant or other contaminants. 5. Connect the New Generation STAR (NGS) tester to the vehicle while the vehicle is parked in the service bay with the engine running. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 7398 6. Install a pressure gauge capable of reading 400 PSI at the front air line (Figure 1). Using the scan tool, command the compressor ON. Check the output of the compressor on the gauge: a. If the compressor does not output at least 110 PSI within 30 seconds, replace the compressor again and retest. NOTE VERIFY THAT THE SUSPENSION RAISES PROPERLY. 7. Using the scan tool, command the front of the vehicle to raise up one inch. The front suspension should rise one inch in 25 seconds or less. a. If the compressor output is near 300 PSI, check4or air line or solenoid restrictions, repair as necessary and retest. Otherwise, proceed to Step 7b. NOTE SUSPENSION UPWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD DECREASE BY .35 TO .45 VOLTS. b. If the front of the vehicle DOES NOT raise, check the front pneumatic system for leaks, inoperable or blocked solenoid valves or pinched air lines. If an issue is found, repair as required and repeat Step 7 to verify proper operation. c. If no problem found, continue to Step 8. NOTE VERIFY THAT SUSPENSION PROPERLY. 8. If the front of the vehicle DOES raise, use the scan tool to command the front of the vehicle to lower one inch. The front suspension should lower one inch in 20 seconds or less. NOTE SUSPENSION DOWNWARD MOVEMENT CAN BE VERIFIED BY MONITORING EITHER OF THE FRONT HEIGHT SENSOR PIDS, WHICH SHOULD INCREASE BY .35 TO .45 VOLTS. a. If the front of the vehicle DOES NOT lower, check the front pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines. Repair air lines or replace solenoid valves as required. 9. Repeat Steps 7 and 8 for the rear. Command the rear of the vehicle, and monitor the rear height sensor PID. Voltages should increase when the vehicle is lowered, and decrease when the vehicle is raised. If the rear of the vehicle does not raise and lower as commanded, inspect the rear pneumatic system for leaks, inoperable or blocked solenoid valves, an inoperable vent solenoid, or pinched air lines, and repair as necessary. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Technical Service Bulletins > Air Suspension - Repeat Compressor Drier Failures > Page 7399 10. If the vehicle raises and lowers normally in both the front and the rear, test drive the vehicle to confirm the repair. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-7-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 304000 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Rear Only System Level Control Solenoid Valve: Service and Repair Rear Only System Functional Removal WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. - Disconnecting an air line that is connected to the air compressor can cause personal injury or damage to components as high pressure air is vented uncontrolled. 1. Remove the air spring assembly. 2. CAUTION: Remove any dirt or other debris from the air spring assembly prior to removing the air spring solenoid from the air spring assembly. Remove the air spring solenoid clip. 3. Twist the air spring solenoid and remove. Installation 1. Note: Inspect the 0-ring for damage and replace as necessary. Lubricate the solenoid seal area with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331A or equivalent meeting Ford specification ESE-M1C171-A. Note: After installing the solenoid, it is necessary to inflate the air suspension system. - When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. To install, reverse the removal procedure. Non-Functional Removal WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Rear Only System > Page 7402 Note: The air spring solenoid has a two-stage pressure relief fitting similar to a radiator cap. 1. Raise and support the vehicle. 2. Disconnect the air spring solenoid electrical connector. 3. Disconnect the air spring solenoid air line. - Compress the quick connect locking ring and pull out the air line. 4. CAUTION: Remove any dirt or other debris from the air spring prior to removing the air spring solenoid from the air spring. Remove the air spring solenoid clip. 5. Rotate the air spring solenoid out of the air spring to the first detent to release the air from the air spring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Rear Only System > Page 7403 6. Remove the air spring retainer. 7. Lift the bottom of the air spring from the rear axle and remove the air spring. 8. Twist the air spring solenoid and remove. Installation 1. Note: Inspect the O-ring for damage and replace as necessary. Lubricate the solenoid seal area with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A. Note: Be sure the new air spring solenoid is fully seated into both stages of the air spring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Rear Only System > Page 7404 - After installing the solenoid, it is necessary to inflate the air suspension system. - When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Rear Only System > Page 7405 Level Control Solenoid Valve: Service and Repair 4-Wheel System Functional Removal WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. - Disconnecting an air line that is connected to the air compressor can cause personal injury or damage to components as high pressure air is vented uncontrolled. 1. Remove the air spring assembly. 2. CAUTION: Remove any dirt or other debris from the air spring assembly prior to removing the air spring solenoid from the air spring assembly. Remove the air spring solenoid clip. 3. Twist the air spring solenoid and remove. Installation 1. Note: Inspect the O-ring for damage and replace as necessary. Lubricate the solenoid seal area with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331A or equivalent meeting Ford specification ESE-M1C171-A. Note: After installing the solenoid, it is necessary to inflate the air suspension system. - When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. To install, reverse the removal procedure. Non-Functional Removal WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Rear Only System > Page 7406 Note: The air spring solenoid has a two-stage pressure relief fitting similar to a radiator cap. 1. Raise and support the vehicle. 2. Disconnect the air spring solenoid electrical connector. 3. Disconnect the air spring solenoid airline. - Compress the quick connect locking ring and pull out the air line. 4. CAUTION: Remove any dirt or other debris from the air spring prior to removing the air spring solenoid from the air spring. Remove the air spring solenoid clip. 5. Rotate the air spring solenoid out of the air spring to the first detent to release the air from the air spring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Rear Only System > Page 7407 6. Remove the air spring retainer. 7. Lift the bottom of the air spring from the rear axle and remove the air spring. 8. Twist the air spring solenoid and remove. Installation 1. Note: Inspect the O-ring for damage and replace as necessary. Lubricate the solenoid seal area with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331A or equivalent meeting Ford specification ESE-M1C171-A. Note: Be sure the new air spring solenoid is fully seated into both stages of the air spring. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level Control Solenoid Valve > Component Information > Service and Repair > Rear Only System > Page 7408 - After installing the solenoid, it is necessary to inflate the air suspension system. - When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. To install, reverse the removal procedure. Inline Removal Note: The vehicle must be positioned on a suitable lifting device prior to deflating the air suspension system. 1. Deflate the air suspension system. 2. Disconnect the battery ground cable. 3. Raise and support the vehicle. 4. Note: Front fill solenoid shown, front gate solenoid and rear fill solenoid similar. Disconnect the electrical connector. 5. Disconnect the solenoid valve air lines. - Compress the red quick connect locking rings and pull out the air lines. 6. Note: Front fill solenoid shown, front gate solenoid and rear fill solenoid similar. Remove the solenoid from the frame. Installation 1. Note: When installing the air lines, make sure the white air line is fully inserted into the fitting for correct installation. Note: After installing the solenoid, it is necessary to inflate the air suspension system. - When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Locations > Front Height Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Locations > Front Height Sensor > Page 7413 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Rear Ride Height Sensor: Service and Repair Rear Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Note: The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. Remove the air suspension height sensor. 1. Disconnect the electrical connector. 2. Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Height Sensor, Suspension Control > Component Information > Service and Repair > Rear > Page 7416 Ride Height Sensor: Service and Repair 4-Wheel System Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Note: The air suspension height sensor has a plastic harness retainer to suspension that must be unclipped prior to removal. Remove the air suspension height sensor. 1. Disconnect the electrical connector. 2. Depress the metal retaining tabs and remove the air suspension height sensor from the ball studs. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7425 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7426 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Control Module: > 00-9-1 > May > 00 > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Control Module: > 00-9-1 > May > 00 > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7438 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Control Module: > 00-9-1 > May > 00 > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7439 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Oil Temperature The Engine Oil Temperature (EOT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and 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. Engine Coolant Temperature (ECT) Sensor The EOT measures the temperature of the engine oil. The EOT sensor is similar in construction to the Engine Coolant Temperature (ECT) sensor. On some applications, EOT input to the PCM is used to initiate a soft engine shutdown. This prevents engine damage from occurring as a result of high oil temperature. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Technical Service Bulletin # 01-12-8 Date: 010625 Air Suspension - Lamp ON/DTC's B2140 or C2140 Set Article No. 01-12-8 06/25/01 ^ SUSPENSION - AIR SUSPENSION - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE ^ ELECTRICAL - LAMP - AIR SUSPENSION LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B2140 OR C2140 - RIDE HEIGHT RESET PROCEDURE FORD: 1997-2001 EXPEDITION LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit a check suspension lamp ON with Diagnostic Trouble Codes (DTC's) B2140 or C2140 even after the Air Suspension switch in the upper RH kick panel has been turned on. This may occur at pre-delivery, following suspension service, or after Air Suspension module replacement. This may be caused by the ride height calibration. ACTION Adjust and/or recalibrate ride height as necessary using the NGS (New Generation Star) Tester. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011208A Recalibrate Ride Height 0.2 Hr. For Rear Air Suspension (R.A.S.) 4X2 Vehicles Only 011208B Recalibrate Ride Height 0.5 Hr. For 4 Wheel Air Suspension (4W.A.S.) (Includes Time To Adjust Torsion Bars 4X4 Vehicles Only) DEALER CODING CONDITION BASIC PART NO. CODE 5A919 42 OASIS CODES: 206000, 304000, 390000 Service Procedure NOTE DURING PDI (PRE-DELIVERY INSPECTION) IF "CK SUSP" LIGHT IS ON, PRIOR TO SENDING TO SERVICE, VERIFY SWITCH IN UPPER RIGHT KICK PANEL IS ON. THIS SWITCH IS TURNED OFF DURING VEHICLE SHIPMENT TO PREVENT MODULE FROM SEEKING TRIM HEIGHT WHILE SECURED DOWN FOR TRANSPORT. NOTE AN INADVERTENT B2140 OR C2140 MAY RESULT IF A PARAMETER RESET (CLEAR RIDE HEIGHT) IS SELECTED UNDER NGS ACTIVE COMMANDS, THEN CANCELLED OUT. NOTE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7450 THE AIR SUSPENSION CONTROL MODULE PART NUMBER IS INTERCHANGEABLE BETWEEN THE REAR AIR SUSPENSION (RAS) AND 4-WHEEL AIR SUSPENSION (4WAS) SYSTEMS, BUT ONCE THE MODULE IS INSTALLED, THE VEHICLE WILL THEN DETERMINE WHETHER VEHICLE IS 4X2 (RAS) OR 4X4 (4WAS) BASED ON VEHICLE HARNESS INPUTS. NOTE MODULES ARE PRE-PROGRAMMED TO SEEK 2.66 VOLTS + 1.02 VOLTS FROM REAR HEIGHT SENSOR (RHGSTEN PARAMETER IDENTIFIER OR PID) AT TRIM HEIGHT. HOWEVER, A NEW OR SWAPPED MODULE REQUIRES CALIBRATION PER STEPS BELOW TO CLEAR A 2140 (INITIALIZATION FAILURE) CODE. NOTE PERFORM 4WAS-AIR SUSP/EVO (ELECTRONIC VARIABLE ORIFICE STEERING) SELF TEST AND MAKE NECESSARY REPAIRS FOR ANY OTHER AIR SUSPENSION DTC'S THAT ARE PRESENT BEFORE ADDRESSING B2140/C2140. WARNING WARNING: BEFORE REPLACING ANY AIR SUSPENSION COMPONENTS, HOISTING, JACKING, OR TOWING, DISCONNECT POWER TO THE SYSTEM BY, TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RIGHT KICK PANEL AREA TO PREVENT VEHICLE DAMAGE OR PERSONAL INJURY. RAS ONLY - CLEAR 2140 NOTE EVEN RAS (4X2) EQUIPPED VEHICLES REQUIRE STORING RIDE HEIGHT AND TOGGLING FRONT TO "ON" TO CLEAR A CK SUSP LIGHT/214O CODE. THIS ALLOWS THE MODULE TO STORE THE VOLTAGE WITH NO FRONT HEIGHT SENSOR PRESENT, AND MUST BE DONE EVEN WITH CONVENTIONAL (STEEL COIL) FRONT SUSPENSION. 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON", press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step # 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional (on-demand) test is in process. As test completes, verify a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off. 4WAS - CLEAR 2140 DTC - Mechanical NOTE OBSERVE AND REPAIR ANY DAMAGED PARTS OR SYSTEM LEAKS, INSPECTING THE AIR LINE UNION LOCATED UNDER THE BRAKE MASTER CYLINDER FIRST. IF BRAKE FLUID HAS DAMAGED THE LINE, REPLACE THEN REROUTE NEW AIR LINE AWAY FROM AN ORIENTATION DIRECTLY UNDER THE MASTER CYLINDER. BRUSH A SOAPY WATER SOLUTION ON REMAINING SYSTEM CONNECTIONS, INCLUDING INLINE AND "T" UNIONS; AIR LINE RUB POINTS; COMPRESSOR FITTINGS; GATE AND FILL SOLENOIDS; AND AIR SHOCKS/SPRINGS. KEEP IN MIND THAT AIR SPRING LEAKS WHERE THE BAG FOLDS OVER ITSELF MAY NOT BE IMMEDIATELY OBVIOUS WITHOUT CYCLING THE SUSPENSION THROUGH DIFFERENT HEIGHTS. IF AIR BUBBLES ARE DETECTED, REPAIR AS NECESSARY THEN RETEST TO ENSURE LEAK-FREE CONNECTIONS BEFORE COMPLETING THE STEPS BELOW. 1. Bring the vehicle to kneel height by turning ignition key off, gear lever in park, doors closed for up to 30 seconds on level ground. Listen for compressor's vent solenoid to release air from lines before proceeding. Venting should occur within approximately one minute of closing all doors Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Customer Interest for Suspension Control Module: > 01-12-8 > Jun > 01 > Air Suspension - Lamp ON/DTC's B2140 or C2140 Set > Page 7451 with the key in the "off" position. 2. Erase the module's memory: ^ Trigger 4WAS active commands, PARAMETER RESET (Clear Ride Height) WARNING DO NOT RESET REAR HEIGHT AT THIS TIME! ^ Trigger thru warning message, then toggle FRONT CLR from "OFF" to "ON" Press Cancel NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION! 3. You have now cleared the front kneel voltage stored in the module and B2140 will be present on next key-up. 4. Bleed air from front shocks: ^ Mark existing torsion bar setting, then back off the torsion bar adjustment bolt several turns (until approximately 40 mm (1.5") distance from the bolt head to the bottom surface of the torsion bar adjuster is reached) ^ Select AIR SUSP CNTRL from active command menu (NGS will return to this after previous steps) ^ Trigger VENT FRONT, then wait several seconds for air to vent. Press Cancel to exit. 5. Adjust torsion bars per Workshop Manual section 204-01B. NOTE LEAVE THE NGS CONNECTED IN ACTIVE COMMAND MODES (ENTERED IN STEP 4) 50 THE SYSTEM REMAINS IN DIAGNOSTIC MODE AND NOT OPERATIONAL MODE. 6. Finish by performing the following electrical front height reset steps. 4WAS - CLEAR 2140 DTC - Electrical 1. Enter 4WAS active commands and trigger on SAVE CAL (Store Ride Height). NOTE YOU MUST DISREGARD WARNING THAT FURTHER ACTION PERMANENTLY WRITES TO THE MODULE AND TRIGGER THROUGH. 2. Trigger through the NGS warning message. NGS screen will now split with active commands on the LH side of screen and any PIDS selected on the right. 3. Toggle FRONT to "ON". press Cancel. NOTE CANCEL MUST BE SELECTED TO COMPLETE THE OPERATION. DO NOT SAVE OR CLEAR REAR RIDE HEIGHT. 4. Retrieve and clear continuous DTC's; at this point a 2140 code should be present. Press NGS # 7 keypad button located directly underneath the word "CLEAR" on the LCD screen, depress trigger per screen prompt, and wait for message stating "system passed - no DTCs available". Earlier NGS software revision levels may require repeating these steps several times before a system pass message is received. 5. Cancel out of continuous test in Step 4 after receiving pass code message. Select on-demand self test, trigger, press NGS # 3 keypad button located directly underneath the word "START" on the LCD screen. Note on-screen instructions to prepare vehicle for test/function then trigger to begin the test. You should hear underhood noise from compressor and relays indicating this functional on-demand test is in process. As test completes, verity a "system passed" message is received. 6. Cancel out of on-demand test, remove NGS tester, start vehicle and verify the check suspension indicator remains off and vehicle height settles out as compressor fills air bladders/shocks. NOTE FOR OTHER AIR SUSPENSION CONCERNS, REFER TO THE APPROPRIATE WORKSHOP MANUAL SECTIONS: 204-05A FOR VEHICLE DYNAMIC SUSPENSION - REAR, OR SECTION 204-05B FOR VEHICLE DYNAMIC SUSPENSION - 4 WHEEL. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Radiator: All Technical Service Bulletins A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 7457 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 7458 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 7459 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Page 7460 Radiator: Specifications Radiator support bracket bolts 22 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Page 7461 Radiator: Service and Repair Removal 1. Remove the fan blade. 2. Disconnect the transmission fluid cooler fittings. 1 Disconnect the upper transmission fluid cooler fitting. 2 Disconnect the lower transmission fluid cooler fitting. 3. Disconnect the lower radiator hose from the radiator. 1 Pry the locking tab up and out of the slot. 2 Rotate the lower radiator hose. 3 Disconnect the lower radiator hose. 4. Remove the radiator. 1 Remove the bolts. 2 Remove the upper radiator support brackets and the jack handle and wheel nut wrench retainers. 3 Lift the radiator off the radiator mounting insulators. 4 Remove the radiator mounting insulators. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Page 7462 1. Install the radiator. 1 Install the radiator mounting insulators. 2 Position the radiator on the radiator mounting insulators. 3 Position the brackets and the jack handle and wheel nut wrench retainers. 4 Install the bolts. 2. Connect the lower radiator hose and upper radiator hose. 1 Push the hose onto quick connect fitting. 2 Bend the locking tab into retaining slot. 3. Connect the transmission fluid cooler lines. 1 Connect the lower transmission fluid cooler line. 2 Connect the upper transmission fluid cooler line. 4. Install the fan blade. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Service and Repair > Component Information > Page 7463 Transmission Speed Sensor: Service and Repair Removal 1. Remove the drive shaft. 2. Remove the rear transmission mount nuts. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Remove the rear transmission mount. 1 Raise the transmission up off the rear crossmember support. 2 Remove the bolts. 3 Remove the rear transmission mount. 4. Lower the transmission to gain access to the Turbine Shaft Speed (TSS) sensor, and the Output Shaft Speed (OSS) sensor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Service and Repair > Component Information > Page 7464 5. Remove the Turbine Shaft Sensor (TSS). 1 Remove the bolt. 2 Remove the Turbine Shaft Sensor (TSS). 6. Remove the Output Shaft Speed (OSS) sensor. 1 Remove the bolt. 2 Remove the Output Shaft Speed (OSS) sensor. Installation 1. Install the Output Shaft Speed (OSS) sensor. 1 Lubricate the O-ring and install the Output Shaft Speed (OSS) sensor. 2 Install the bolt. 2. Install the Turbine Shaft Sensor (TSS). 1 Lubricate the O-ring and install the Turbine Shaft Sensor (TSS). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Service and Repair > Component Information > Page 7465 2 Install the bolt. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the sensors will occur. Install the rear transmission mount. 1 Raise the transmission up. 2 Install the rear transmission mount. 3 Install the bolts. 4. Lower the transmission on to the rear crossmember support. 5. Install the rear transmission mount nuts. 6. Install the drive shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Specifications Suspension Mode Switch: Specifications Air Suspension Switch Bracket Mounting Bolt .................................................................................................................. 10.2-13.8 Nm (91-123 inch lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Service and Repair > Rear Only System Suspension Mode Switch: Service and Repair Rear Only System Removal 1. Disconnect the battery ground cable. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. 4. Disconnect the air suspension switch electrical connector. 5. Remove the air suspension switch bracket mounting bolt. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Service and Repair > Rear Only System > Page 7471 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Service and Repair > Rear Only System > Page 7472 Suspension Mode Switch: Service and Repair 4-Wheel System Removal 1. Disconnect the battery ground cable. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. 4. Disconnect the air suspension switch electrical connector. 5. Remove the air suspension switch bracket mounting bolt. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Service and Repair > Rear Only System > Page 7473 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair Suspension Spring ( Coil / Leaf ): Service and Repair Removal 1. Raise and support the vehicle. 2. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and the wheel bearings. Remove the wheel and tire assembly. 3. Remove the driveshaft. 4. Disconnect the rear Brake Anti-Lock Sensor (ABS) electrical connector. 5. Note: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1. Pull the front parking brake cable and conduit. 2. Insert a suitable retainer into the parking brake control. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Page 7477 6. Disconnect the rear parking brake cable and conduit from the rear axle. 1. Remove the rear parking brake cable and conduit from the rear axle bracket assembly. 2. Remove the cable from the caliper. - Repeat for the other side. 7. Position the disc brake caliper aside. 1. Remove the bolts. 2. Secure the caliper aside with wire. - Repeat for the other side. 8. Disconnect the axle vent tube. 9. Disconnect the stabilizer bar from the rear axle. 1. Remove the bolts from each stabilizer bar retainer. 2. Remove the retainers. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Page 7478 10. Use the High-Lift Jack to support the rear axle. 11. Remove the lower shock absorber nut and bolt. - Repeat for the other side. 12. Remove the rear axle-to-trackbar assembly bolt. 13. Remove the rear suspension lower arm assembly-to-axle bolt. - Repeat for the other side. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Page 7479 14. Remove the rear suspension upper arm assembly-to-rear axle bolt. - Repeat for the other side. 15. Lower the rear axle and remove the coil spring. Installation Note: Do not tighten any nuts or bolts until the rear suspension is raised so that the rear suspension lower arms are parallel to the ground. Once in position, tighten all the nuts and bolts to specification. 1. Install the rear coil spring. 2. Position the rear suspension upper arm assemblies to the axle and install the bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Page 7480 3. Position the rear suspension lower arm assemblies to the axle and install the bolts. 4. Position the trackbar assembly to the axle and install the bolts. 5. Position the shock absorbers to the axle and install the bolts. 6. Position the stabilizer bar to the axle and install the stabilizer bar retainers and bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Page 7481 7. Position the disc brake caliper. 1. Position the caliper. 2. Install the bolts. 8. Connect the parking brake cables and conduit to the axle. 1. Install the cable and conduit to the lever. 2. Install the cable and conduit to the rear axle bracket assembly. 9. Install the tire and wheel assembly. 10. Remove the pin from the parking brake control assembly. 11. Connect the rear Brake Anti-Lock Sensor (ABS) electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Page 7482 12. Connect the axle vent tube. 13. Install the driveshaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications Suspension Strut / Shock Absorber: Specifications Front Shock Absorber Lower Bolt And Nut ................................................................................................................................ 88-118 Nm (65-87 ft. lbs.) Front Shock Absorber Upper Nut .................................................................................................................................................. 30-40 Nm (22-29 ft. lbs.) Rear Shock Absorber-To-Axle Nut .............................................................................................................................................. 86-114 Nm (63-84 ft. lbs.) Rear Shock Absorber-To-Frame Nut ........................................................................................................................................... 86-114 Nm (63-84 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Page 7486 Suspension Strut / Shock Absorber: Testing and Inspection CAUTION: The low pressure gas shock absorbers are charged with nitrogen gas to 931 kPa (135 psi) for 1-3/16 inch bore, and 1034 kPa (150 psi) for 1-3/8 inch bore. Do not attempt to open, puncture, or apply heat to the shock absorbers. All vehicles are equipped with low pressure gas-filled hydraulic shock absorbers of the direct acting type. They are non-adjustable and non-refillable. They cannot be serviced as cartridges and must be serviced as shock assemblies. Before replacing a shock absorber, check the action of the shock absorbers as follows. Vehicle Inspection 1. Check all tires for proper inflation pressure. 2. Check tire condition to confirm proper front end alignment, tire balance and overall tire condition such as separation or bulges. 3. Check the vehicle for optional suspension equipment such as heavy-duty handling or trailer tow suspensions. These suspensions will have a firmer feeling ride than standard suspensions. 4. Check the vehicle attitude for evidence of possible overload or sagging. Many times, front springs and front shock absorbers are replaced in an effort to solve a vehicle sag concern. Shock absorbers are, by design, hydraulic damping units only and unlike suspension springs, do not support any suspension loads. Therefore, replacing a shock absorber will not correct a vehicle sag concern. 5. Road test the vehicle to confirm the customer concern. 6. Make sure the shock absorber is securely and properly installed. 7. Check the shock absorber insulators for damage and wear. 8. Replace any worn or damaged insulators and tighten attachments to the specified torque (on a shock absorber which incorporates internal insulators, replace the shock absorbers). 9. Tighten the shock absorber attachments to the specified torque. 10. Inspect the shock absorber for evidence of fluid leakage. Leakage is a condition in which the entire shock body is covered with oil, and the oil will drip from the shock onto the pavement. A light film of oil (weepage) on the upper portion of the front shock absorber is permissible and is a result of proper shock lubrication. Weepage is a condition in which a thin film of oil may be deposited on the shock outer tube (body) and is normally noticed due to the collection of dust in this area. Front shock absorbers which exhibit this weepage condition are functional units and should not be replaced. 11. If leakage exists: - Make sure the fluid observed is not from sources other than the front shock absorber. - Replace the worn or damaged front shock absorber. 12. Disconnect the lower end of the shock absorber. 13. Extend and compress the shock absorber as fast as possible, using as much travel as possible. Action should become smooth and uniform throughout each stroke. Higher resistance on extension than on compression is a normal condition. - Faint swish noises are also normal. Hoist Check WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Noise: Check for loose/damaged suspension or shock attachments when locating a noise symptom, Verify that all the attachments or the suspension components and the front springs and front shock absorbers arc in good condition and tight. Replace any worn or damaged parts or components. 2. Bottom/Hopping: Check the condition of the rubber suspension travel stops ( front suspension bumpers). Examine them for evidence of previous overload or damaged components; replace them if they are worn or missing. 3. Force-Check: Support the front axle and remove the lower front shock attachment. Stroke the front shock body using as much travel as possible. The action should be smooth and uniform throughout each stroke. Damping forces should be equivalent on both sides of the vehicle. 4. Replace only the worn or damaged front shock absorber. In the past, it was recommended that front shock absorbers be replaced in pairs if one unit became unserviceable. Improved sealing, new materials, design, and improved rod machining and hardening techniques have added to the reliability of shock absorbers. Therefore, front shock absorbers no longer need to be replaced in pairs when only one unit is not serviceable. Bench Test The front shock absorbers are gas-pressurized, which results in their being fully extended when not restrained. If a front shock absorber does not fully extend, it is damaged and should be replaced. With the front shock absorber in the normal upright position, compress it and allow it to extend three times to purge the pressure chamber of any gas that may have been introduced during handling. Place the front shock absorber right side up in a vise. Hand-stroke the front shock absorber as fast as possible using as much travel as possible. Action should be smooth and uniform throughout each stroke. Higher resistance on extension than on compression is normal. The following conditions are abnormal: A lag or skip at a reversal of travel near mid-stroke when the front shock absorber is properly primed and in the installed position. - Seizing. - Noise, other than a faint swish, such as a clicking upon fast stroke reversal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Page 7487 - Excessive fluid leakage. - With rod fully extended, any lateral motion of rod in relation to outer cylinder. If front shock absorber action remains erratic after purging air, install a front shock absorber, replacing only the damaged front shock absorber. Front shock absorbers do not need to be replaced in pairs. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear Suspension Strut / Shock Absorber: Service and Repair Rear Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and the wheel bearings. Remove the tire and wheel assembly. 3. Use the High-Lift Jack to support the rear axle. 4. Remove the upper shock absorber nut and bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear > Page 7490 5. Remove the lower shock absorber nut, bolt and the shock absorber. Installation 1. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and allow the wheel to come off while the vehicle is in motion, causing loss of control. Note: Tighten the wheel nuts in sequence. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear > Page 7491 Suspension Strut / Shock Absorber: Service and Repair Shock Absorber Removal 1. Hold the shock absorber stem and remove the upper front shock absorber nut, and washer assembly. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Remove the shock absorber. 1. Remove the lower nut and bolt. 2. Remove the shock absorber. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear > Page 7492 1. Follow the removal procedure in reverse order. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications Torsion Bar: Specifications Torsion Bar Crossmember Support Bolts ...................................................................................................................................... 40-54 Nm (29-40 ft. lbs.) Torsion Bar Crossmember Support Nuts ....................................................................................................................................... 53-72 Nm (39-53 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 7496 Torsion Bar: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Make preliminary adjustment references. 1. Make an alignment mark on the torsion bar and the torsion bar crossmember support. 2. Measure and record the length. 3. Relieve the torsion bar tension. 1. Remove the torsion bar adjuster bolt. 2. Install the Torsion BarTool with the Torsion Bar Tool Adapters in the B slots on the Torsion BarTool. 3. Tighten the Torsion Bar Tool until the torsion bar adjuster lifts off of the adjuster nut. 4. Remove the torsion bar adjuster nut. 5. Remove the Torsion Bar Tool. 6. Remove the torsion bar adjuster. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 7497 4. Remove the torsion bars. 1. Remove the torsion bar crossmember support bolts and nuts. 2. Remove the torsion bar crossmember support. 3. Remove the torsion bars. Installation 1. Install the torsion bar. 1. Position the torsion bars. 2. Position the torsion bar crossmember support. 3. Install the torsion bar crossmember support bolts and nuts. 2. Load the torsion bar. 1. Install the torsion bar adjuster. - Turn the torsion bar adjuster until the reference marks align. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 7498 2. Install the Torsion Bar Tool with the Torsion Bar Tool Adapters in the B slots on the Torsion BarTool. 3. Tighten the Torsion Bar Tool to load the torsion bar. 4. Install the torsion bar adjuster nut. 5. Install the torsion bar adjuster bolt. 6. Remove the Torsion Bar Tool. 3. Adjust the ride height. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricate the new rear wheel bearing. - Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 7502 Wheel Bearing: Testing and Inspection Wheel Bearing Check 1. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Spin the tire by hand to check the wheel bearings for roughness. NOTE: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 7503 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate service procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Ford Wheel Bearing: Service and Repair Ford Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. 3. Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing, and the wheel bearing oil seal. Installation 1. Lubricate the new rear wheel bearing. - Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Ford > Page 7506 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Ford > Page 7507 Wheel Bearing: Service and Repair Front Removal Note: The wheel bearing and hub are installed as an assembly. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and wheel bearings. Remove the wheel and tire assembly. 3. Remove the brake disc. 4. Remove the front wheel hub nut. 1. Remove and discard the cotter pin. 2. Remove the retainer. 3. Remove the nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Ford > Page 7508 5. Remove the brake disc shield. 1. Remove the bolts. 2. Remove the brake disc shield. 6. Remove the front brake anti-lock sensor. 1. Remove the bolt. 2. Remove the front brake anti-lock sensor. 7. CAUTION: Do not over-extend the CV joint and boots when removing the hub and bearing assembly. Note: The CV joint is a slip fit into the wheel hub and bearing. A puller will not normally be required. Remove the wheel hub. 1. Remove the bolts. 2. Push the CV joint inboard. Remove the wheel hub. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Ford > Page 7509 8. Remove the seal. Installation 1. Install the seal using the Knuckle Seal Replacer, the Threaded Drawbar and Bearing Cup Replacer. 2. Install the wheel hub. 1. Position the wheel hub on the front wheel driveshaft and joint and into the front wheel knuckle. 2. Install the wheel hub bolts. 3. Install the front brake anti-lock sensor. 1. Install the front brake anti-lock sensor into the wheel hub. 2. Install the front brake anti-lock sensor bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Ford > Page 7510 4. Install the brake disc shield and front axle hub nut. 1. Position the brake disc shield. 2. Install the bolts. 3. Install the front axle hub nut. 4. Install the retainer. 5. Install a new cotter pin. 5. Install the brake disc. 6. WARNING: When the wheel is installed, always remove any corrosion, dirt or foreign material that may be present on the mounting surfaces of the wheels or the surfaces of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can cause the wheel nut to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. WARNING: ^ Retighten at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened. ^ Failure to retighten wheel nuts at the mileage specified could allow wheels to come off while the vehicle is in motion, possibly causing loss of vehicle control and collision. Install the tire and wheel assembly. 7. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Hub Nut .............................................................................................................................. ................................. 255-345 Nm (188-254 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: ^ THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. ^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. ^ SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. ^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. ^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK CAUTION: Never use a halfshaft as a lifting point. Jacking Points - Front, 4x4 The jacking point is a raised boss located on the front suspension lower arm. Jacking Points - Front, 4x2 The jacking point is a flat portion on the frame indicated by an arrow cutout in the frame, located behind the front tire and wheel assembly. Jacking Points - Rear Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 7519 CAUTION: Never use the differential housing as a lifting point. The rear jacking points are located on the rear axle. LIFTING WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. Lifting Points - Twin Post Hoist Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. Lifting Points - Drive On Hoist The vehicle is supported by tires and suspension components. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair Spare Tire: Service and Repair Removal 1. Lower the spare tire. 1. Insert the drive end of the jack handle through the opening left of the license plate. 2. Turn the jack handle until slack is present in the cable. 2. Remove the spare tire. 1. Slide the retainer through the center of the spare tire assembly. 2. Remove the spare tire assembly. 3. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 4. Remove the spare tire carrier. 1. Remove the bolts. 2. Turn the spare tire carrier to disengage the spare tire carrier from the tabs and remove the spare tire carrier. Installation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair > Page 7524 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Correct Lug Nut Torque Specifications Wheels: Technical Service Bulletins Wheels - Correct Lug Nut Torque Specifications Article No. 03-22-4 11/10/03 WHEEL - CORRECT LUG NUT TORQUE SPECIFICATIONS - INCREASED WHEEL NUT AND STUD SIZE - SERVICE TIP FORD: 2000-2004 EXPEDITION, F-150 LINCOLN: 2000-2004 NAVIGATOR This article supersedes TSB 99-26-3 to update the vehicle model years. ISSUE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Correct Lug Nut Torque Specifications > Page 7529 All 2000-2004 F-150 (excluding F-150 equipped with 7-stud wheels and the 7700 payload group) and Expedition/Navigator built on or after November 27, 1999 will have revised wheel stud and wheel nut diameters. The wheel studs/nuts wilt have increased thread diameter from 12 mm to 14 mm. This change will include revised wheels, center wheel ornaments, hubs, brake rotors, wheel nuts, and lug wrench (two piece design and 13 cm (5") longer). ACTION The 14 mm wheel nut will require a 21 mm socket, instead of the 19 mm socket used on the 12 mm wheel nuts. The torque specification for the l4mm wheel nuts is 200 N.m (150 lb-ft). A TORQUE WRENCH MUST BE USED TO INSURE PROPER TORQUE IS ACHIEVED. The torque specification for the 12 mm wheel nut will remain at 133 N.m (100 lb-ft). NOTE THE 14 mm PARTS ARE NOT INTERCHANGEABLE WITH THE PREVIOUS 12 mm PARTS. CAUTION WHENEVER WHEEL/TIRE REMOVAL AND INSTALLATION IS REQUIRED, FOLLOW THE PROCEDURES AS OUTLINED IN THE APPROPRIATE WORKSHOP MANUAL (SECTION 204). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Correct Lug Nut Torque Specifications > Page 7530 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-26-3 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Correct Lug Nut Torque Specifications > Page 7531 Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Correct Lug Nut Torque Specifications > Page 7532 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7533 Wheels: Specifications Maximum Wheel Rim Runout (Radial Or Lateral) .............................................................................................................................. 1.12 mm (0.044 inch) Maximum Balance Weight (Total Of Inner And Outer Wheel Flanges) ........................................................................................................... 170 g (6 oz.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7534 Wheels: Service Precautions WARNING: Never run the engine with one wheel off the ground, for example, when changing a tire. The wheel resting on the ground could cause the vehicle to move. - The tire and wheel must always be correctly matched. It is very important to determine the size of each component before any assembly operations commence. Do not mount a 16-inch tire on a 16.5-inch wheel. Failure to adhere to these instructions can result in an explosive separation and cause serious bodily injury or death. Do not mount a 16.5-inch tire on a 16-inch wheel. The tire can come off without warning. - Aftermarket aerosol tire sealants are extremely flammable. Always question the customer to make sure these products have not been used. - Use only wheels and wheel nuts that have been designed for current model year ford trucks. Aftermarket wheels or wheel nuts may not fit or function correctly, and can cause personal injury or damage the vehicle. - Always wear safety goggles or a face shield when performing any work with tire and wheel assemblies. - Retighten the wheel nuts at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened. - Failure to retighten wheel nuts at the mileage specified can allow wheels to come off while the vehicle is in motion, possibly causing loss of vehicle control and collision. CAUTION: Do not clean aluminum wheels with steel wool, abrasive-type cleaners or strong detergents. Use Custom Bright Metal Cleaner .8A-19522-A or equivalent meeting Ford specification ESR-M5B194-B. - Reduce the air pressure as much as possible by pushing the valve core plunger in prior to removing the valve core. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7535 Wheels: Description and Operation WARNING: Do not mix different types of tires, such as radial, bias, or bias-belted, on the same vehicle except in emergencies (temporary spare usage). Vehicle handling can be seriously affected and can result in loss of control. Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures. Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increase tire wear. Replacement tires should follow the recommended: tire sizes. - speed rating. - load range. - radial construction type. Use of any other tire size or type may seriously affect: ride. - handling. - speedometer/odometer calibration. - vehicle ground clearance. - tire clearance between the body and chassis. - Wheel bearing life. - brake cooling. New wheels need to be installed when: bent. - dented. - heavily rusted. - leaking. - they have elongated wheel hub bolt holes. - they have excessive lateral or radial runout. The Expedition uses a two-piece wheel nut, containing the nut and a washer. Wheel and tire assemblies are attached by five noncentering wheel nuts. When balancing wheels and tires, use T-type balancing weights. The spare tire is mounted under the frame. The valve stem should. be on the top side of the tire to reduce the possibility of accidental valve stem air leakage. To equalize tire wear, rotate the tires periodically. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire Wheels: Service and Repair Wheel and Tire Removal 1. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and wheel bearings. Note: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the wheel nuts. 1. Remove the center cap. 2. With the weight of the vehicle on the wheels, loosen the wheel nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Remove the wheel and tire assembly. 1. Remove the wheel nuts. 2. Remove the wheel and tire assembly using a side-to-side rocking motion. Installation All vehicles 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. WARNING: Retighten at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened. - Failure to retighten wheel nuts at the mileage specified could allow wheels to come off while the vehicle is in motion, possibly causing loss of vehicle control and collision. Clean the wheel hub mounting surface. 2. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the tire and wheel assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire > Page 7538 - Position the tire and wheel assembly. - Install the wheel nuts, hand-tight, then lower the vehicle. Vehicles with 12 mm wheel bolts 3. CAUTION: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the wheel nuts in sequence. Vehicles with 14 mm wheel bolts 4. CAUTION: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the wheel nuts in sequence. All vehicles 5. Install the center cap. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Wheel and Tire > Page 7539 Wheels: Service and Repair Wheel Leaks CAUTION: Do not attempt to repair aluminum wheels that leak air. 1. If repairs are made to the wheel, the structural integrity of the wheel can be lost. Install a new aluminum wheel if it leaks air. 2. Install new or repair any wheel that leaks air. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Page 7540 Special Tools Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricate the new rear wheel bearing. - Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 7544 Wheel Bearing: Testing and Inspection Wheel Bearing Check 1. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 2. Spin the tire by hand to check the wheel bearings for roughness. NOTE: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 7545 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate service procedures. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Ford Wheel Bearing: Service and Repair Ford Special Tools Removal 1. Remove the axle shaft. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. 3. Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material. Using the special tools, remove the rear wheel bearing, and the wheel bearing oil seal. Installation 1. Lubricate the new rear wheel bearing. - Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Ford > Page 7548 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Ford > Page 7549 Wheel Bearing: Service and Repair Front Removal Note: The wheel bearing and hub are installed as an assembly. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and wheel bearings. Remove the wheel and tire assembly. 3. Remove the brake disc. 4. Remove the front wheel hub nut. 1. Remove and discard the cotter pin. 2. Remove the retainer. 3. Remove the nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Ford > Page 7550 5. Remove the brake disc shield. 1. Remove the bolts. 2. Remove the brake disc shield. 6. Remove the front brake anti-lock sensor. 1. Remove the bolt. 2. Remove the front brake anti-lock sensor. 7. CAUTION: Do not over-extend the CV joint and boots when removing the hub and bearing assembly. Note: The CV joint is a slip fit into the wheel hub and bearing. A puller will not normally be required. Remove the wheel hub. 1. Remove the bolts. 2. Push the CV joint inboard. Remove the wheel hub. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Ford > Page 7551 8. Remove the seal. Installation 1. Install the seal using the Knuckle Seal Replacer, the Threaded Drawbar and Bearing Cup Replacer. 2. Install the wheel hub. 1. Position the wheel hub on the front wheel driveshaft and joint and into the front wheel knuckle. 2. Install the wheel hub bolts. 3. Install the front brake anti-lock sensor. 1. Install the front brake anti-lock sensor into the wheel hub. 2. Install the front brake anti-lock sensor bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Ford > Page 7552 4. Install the brake disc shield and front axle hub nut. 1. Position the brake disc shield. 2. Install the bolts. 3. Install the front axle hub nut. 4. Install the retainer. 5. Install a new cotter pin. 5. Install the brake disc. 6. WARNING: When the wheel is installed, always remove any corrosion, dirt or foreign material that may be present on the mounting surfaces of the wheels or the surfaces of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can cause the wheel nut to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. WARNING: ^ Retighten at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened. ^ Failure to retighten wheel nuts at the mileage specified could allow wheels to come off while the vehicle is in motion, possibly causing loss of vehicle control and collision. Install the tire and wheel assembly. 7. Note: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Axle Hub Nut .............................................................................................................................. ................................. 255-345 Nm (188-254 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Wheels - Correct Lug Nut Torque Specifications Wheel Fastener: Technical Service Bulletins Wheels - Correct Lug Nut Torque Specifications Article No. 03-22-4 11/10/03 WHEEL - CORRECT LUG NUT TORQUE SPECIFICATIONS - INCREASED WHEEL NUT AND STUD SIZE - SERVICE TIP FORD: 2000-2004 EXPEDITION, F-150 LINCOLN: 2000-2004 NAVIGATOR This article supersedes TSB 99-26-3 to update the vehicle model years. ISSUE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Wheels - Correct Lug Nut Torque Specifications > Page 7561 All 2000-2004 F-150 (excluding F-150 equipped with 7-stud wheels and the 7700 payload group) and Expedition/Navigator built on or after November 27, 1999 will have revised wheel stud and wheel nut diameters. The wheel studs/nuts wilt have increased thread diameter from 12 mm to 14 mm. This change will include revised wheels, center wheel ornaments, hubs, brake rotors, wheel nuts, and lug wrench (two piece design and 13 cm (5") longer). ACTION The 14 mm wheel nut will require a 21 mm socket, instead of the 19 mm socket used on the 12 mm wheel nuts. The torque specification for the l4mm wheel nuts is 200 N.m (150 lb-ft). A TORQUE WRENCH MUST BE USED TO INSURE PROPER TORQUE IS ACHIEVED. The torque specification for the 12 mm wheel nut will remain at 133 N.m (100 lb-ft). NOTE THE 14 mm PARTS ARE NOT INTERCHANGEABLE WITH THE PREVIOUS 12 mm PARTS. CAUTION WHENEVER WHEEL/TIRE REMOVAL AND INSTALLATION IS REQUIRED, FOLLOW THE PROCEDURES AS OUTLINED IN THE APPROPRIATE WORKSHOP MANUAL (SECTION 204). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Wheels - Correct Lug Nut Torque Specifications > Page 7562 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-26-3 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 7563 Wheel Fastener: Specifications Vehicles with 12 mm wheel bolts Tighten the wheel nuts in sequence to 135 Nm (100 ft. lbs.). Vehicles with 14 mm wheel bolts Tighten the wheel nuts in sequence to 204 Nm (150 ft. lbs.). CAUTION: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 7564 Wheel Fastener: Service and Repair Removal 1. Remove the wheel hub. 2. CAUTION: Do not press on the bearing when removing or installing wheel studs. Remove the damaged wheel studs. Installation 1. CAUTION: Do not press on the bearing when removing or installing wheel studs. Install the new wheel studs. 2. Install the wheel hub. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications Accumulator HVAC: Specifications Suction Accumulator Clamp Bracket Bolt 9 - 11.2 Nm Junction block bracket screw 12 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7569 Accumulator HVAC: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7570 A/C Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7571 Refrigerant System Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7572 Accumulator HVAC: Description and Operation Suction Accumulator/Drier NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The suction accumulator is mounted to the A/C accumulator bracket to the right of the vehicle centerline. The inlet tube of the suction accumulator attaches directly to the A/C evaporator core outlet tube and the outlet tube of the suction accumulator attaches to the A/C manifold and tube. After entering the inlet of the suction accumulator, heavier oil-laden refrigerant contacts an internally mounted dome (which serves as an umbrella) and drips down onto the bottom of the canister. ^ A small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. ^ As the heavier mixture passes through the small diameter liquid bleed hole, it has a second chance to vaporize and recirculate through the A/C compressor without causing compressor damage due to slugging. ^ A fine mesh screened filter fits tightly around the bottom of the vapor return tube to filter out refrigerant system contaminant particles. ^ A desiccant bag is mounted inside the canister to absorb any moisture which may be in the refrigerant system. ^ A fitting located on the top of the suction accumulator is used to attach the A/C cycling switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C cycling switch can be removed without discharging the A/C system. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7573 Accumulator HVAC: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Perform the Refrigerant Discharging and Recovery Procedure. 3. Remove the junction block splash shield. 4. Disconnect the cable ends. 5. Remove the junction block bracket. 1 Disengage the connector. 2 Remove the screws. 3 Remove the junction block bracket. 6. Disconnect the A/C cycling switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7574 7. Disconnect the manifold and tube assembly spring lock coupling from the suction accumulator. 8. Remove the suction accumulator bracket clamp bolt. 9. Disconnect the suction accumulator spring lock coupling from the A/C evaporator core. 10. Remove the suction accumulator. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7575 11. Remove the A/C cycling switch from the top of the suction accumulator. INSTALLATION 1. To install, reverse the removal procedure. ^ Service the new suction accumulator with the correct amount of PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C), or equivalent, meeting Ford specification WSH-M1C231-B. See: Service and Repair/Refrigerant Oil Addition Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 7576 Accumulator HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Service and Repair Air Conditioning Switch: Service and Repair REMOVAL 1. Remove the control assembly. For additional information, refer to Control Assembly-Manual A/C. 2. Remove the function selector. 1 Depress the snap tabs. 2 Remove the function selector. NOTE: The knob will drop off as the function selector is removed. 3. Remove the temperature blend control switch. 1 Remove the screw. 2 Rotate and pull the temperature blend control switch. NOTE: The knob will drop off as the temperature blend control switch is removed. 4. Remove the blower motor switch. 1 Depress the snap tabs. 2 Remove the blower motor switch. NOTE: The knob will drop off as the blower motor switch is removed. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations Air Door Actuator / Motor: Locations Component Views Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 7584 Component Views Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Air Door Actuator / Motor, HVAC Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Air Door Actuator / Motor, HVAC > Page 7587 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Air Door Actuator / Motor, HVAC > Page 7588 Air Door Actuator / Motor: Diagrams Auxiliary A/C Blend Door Actuator Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Air Door Actuator / Motor, HVAC > Page 7589 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 7590 Air Door Actuator / Motor: Description and Operation The A/C electric blend door actuator is located on the plenum assembly. ^ Its function is to move the air temperature blend door on command from the control assembly. ^ The A/C electric blend door actuator contains a reversible electric motor and a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the air temperature blend door. ^ A 5 volt signal is applied to the ends of the potentiometer. The voltage available at the wiper indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is sent to the EATC module and is compared to the desired wiper voltage determined by the EATC module. The control module then drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the desired wiper voltage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor Air Door Actuator / Motor: Service and Repair Blend Door Motor Main Climate Control REMOVAL 1. Remove the rear seat floor duct. 2. Remove the electronic actuator. 1 Disconnect the connector. 2 Remove the screws. 3 Pull down to release the actuator shaft and remove the electronic actuator. INSTALLATION 1. To install, reverse the removal procedure. Auxiliary Climate Control REMOVAL NOTE: The auxiliary blend door actuator is shown; the auxiliary mode door actuator is similar. 1. Remove the LH quarter trim panel. 2. Remove the electronic actuator. 1 Disconnect the connector. 2 Remove the screws. 3 Remove the electronic actuator. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor > Page 7593 Air Door Actuator / Motor: Service and Repair Air Door Actuator / Motor, HVAC Air Inlet Duct Door Vacuum Control Motor REMOVAL 1. Remove the plenum chamber. 2. Remove the air inlet door vacuum control motor. 1 Disconnect the vacuum line. 2 Remove the vacuum control motor screws. 3 Remove the air inlet door vacuum control motor. ^ Rotate the vacuum control motor to disconnect the vacuum control motor rod from air inlet door lever. INSTALLATION 1. To install, reverse the removal procedure. Panel/Defrost Door Vacuum Control Motor REMOVAL 1. Remove the panel/defrost door vacuum control motor. 1 Disconnect the vacuum line. 2 Remove the pushnut. 3 Remove the vacuum control motor screws. 4 Remove the panel/defrost door vacuum control motor. INSTALLATION 1. To install, reverse the removal procedure. Panel/Floor Door Vacuum Control Motor REMOVAL 1. Remove the floor duct. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor > Page 7594 2. Remove the panel/floor door vacuum control motor. 1 Disconnect the vacuum line connector. 2 Remove the vacuum control motor screws. 3 Slide the rod out of the door and remove the panel/floor door vacuum control motor. NOTE: Rotate the vacuum control motor to disconnect the vacuum control motor rod from the panel/floor door. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor > Page 7595 Air Door Actuator / Motor: Service and Repair Temperature Blend Door Actuator Temperature Blend Door Actuator Removal All vehicles 1. Depower the supplemental restraint system (SRS). See: Restraint Systems/Air Bag Systems Vehicles equipped with floor console 2. Remove the floor console. See: Body and Frame/Interior Moulding / Trim/Console All vehicles 3. Remove the floor duct panel. Remove the pin-type retainers and release the expander clip 4. Remove the RH instrument panel brace. 1. Remove the nut. 2. Remove the bolt. 3. Remove the brace. 5. Remove the LH instrument panel lower nut and position the brace aside. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor > Page 7596 6. Disconnect the restraints control module (RCM) electrical connector. 7. Remove the RCM and bracket assembly. 1. Remove the bracket retaining bolts. 2. Remove the RCM and bracket assembly. Vehicles equipped with rear airflow duct 8. Cut the rear seat airflow duct along both sides. - Fold back carpet. Cut rear seat airflow duct. 9. Fold the air duct rearwards. All vehicles 10. Remove the floor duct. 1. Remove the two screws (one each side). 2. Remove the floor duct. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor > Page 7597 11. Remove the electronic blend door actuator. 1. Disconnect the connector. 2. Remove the screws. 3. Pull down to release the actuator shaft and remove the electronic blend door actuator. Installation All vehicles 1. Install the electronc blend door actuator. 1.8GConnect the actuator shaft. 2. Install the screws. 3. Connect the connector. 2. Install the floor duct. 1. Install the floor duct. 2. Install the two screws (one each side). Vehicles equipped with rear airflow duct 3. Zip-tie the rear airflow duct to floor duct. 4. Reposition the carpet. All vehicles WARNING: The tightening torque of the restraints control module (RCM) retaining bolts is critical for correct system operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Motor > Page 7598 5. Instal the RCM and bracket assembly. 6. Connect the restraints control module (RCM) electrical connector. 7. Install the LH instrument panel lower nut. 8. Install the RH instrument panel brace. 1. Install the brace. 2. Install the bolt. 3. Install the nut. 9. Instal the floor duct panel Install the pin-type retainers and release the expander clip. Vehicles equipped with floor console 10. Install the floor console. See: Body and Frame/Interior Moulding / Trim/Console All vehicles 11. Repower the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > Customer Interest for Air Duct: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents Air Duct: Customer Interest A/C - White Flakes Are Blowing From Dash Vents TSB 09-21-6 11/02/09 WHITE FLAKES COMING FROM A/C VENTS FORD: 2005-2009 Focus 2008-2010 Crown Victoria 2000-2005 Expedition, F-150 2007-2009 Edge 2008-2010 Escape Hybrid, Escape LINCOLN: 2008-2010 Town Car 2000-2005 Navigator 2007-2009 MKX MERCURY: 2008-2010 Grand Marquis, Mariner Hybrid, Mariner This article supersedes TSB 9-19-16 to update the Service Procedure. ISSUE Some vehicles may experience white flakes coming from the A/C vents when the blower motor is engaged. This may be caused by flux utilized in the manufacturing process of the evaporator core. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Hazard and Risk Warnings for White Flakes WARNING MAY CAUSE EYE AND RESPIRATORY TRACT IRRITATION. PROLONGED REPEATED EXPOSURE MAY CAUSE BONE DAMAGE (FLUOROSIS) AND HARM TO THE RESPIRATORY SYSTEM (BASED ON ANIMAL DATA). ^ Avoid inhaling dust. ^ Avoid contact with eyes. ^ Store away from acids. ^ Wash thoroughly after handling. ^ Avoid release to the environment. NOTE THE USE OF DUST PROOF GOGGLES, CHEMICAL RESISTANT GLOVES (PVC) AND DUST MASK IS RECOMMENDED. Using compressed air (maximum inlet pressure) 100 PSI (689 kPa), clean the A/C ducts through the registers and blow off the evaporator core through the blower motor opening. NOTE THE ENTIRE EVAPORATOR CORE SURFACE MUST BE DRY FOR BEST RESULTS. NOTE WHILE PERFORMING THIS PROCEDURE AND SELECTING DIFFERENT VENT MODES SUCH AS FLOOR / PANEL AND FLOOR / DEFROST, IT MAY BE NECESSARY TO TEMPORARILY START THE ENGINE TO ENABLE MODE DOOR MOVEMENT. Clean A/C Ducts: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > Customer Interest for Air Duct: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 7607 1. Remove floor duct trim. 2. Using masking tape, connect one end of the vacuum cleaner hose to the floor duct on driver side. 3. Tape closed all the other floor duct openings. 4. Obtain about two feet (61 cm) of rubber vacuum line large enough to fit the end of a small shop air blowgun. Secure the hose to the end of the blowgun using a worm clamp. 5. Close all instrument panel registers. 6. Set temperature setting to full cold. 7. Place mode in floor / panel. 8. Turn on vacuum cleaner. 9. Working with one register at a time insert the vacuum line down each duct and blow shop air through each duct for 30 seconds. Be sure to close each register before moving on to the next register. 10. Change mode to floor I defrost. 11. Blow down each defroster duct for 30 seconds. 12. Alternate mode door between floor and floor / defrost three (3) times, giving the door time to move between each change. 13. Turn off vacuum cleaner. Clean Evaporator Core: 1. Change mode to full floor. 2. Ensure temperature is full cold. 3. Remove blower motor per Workshop Manual (WSM), Section 412. 4. Turn on vacuum cleaner. 5. Reach into blower opening with vacuum line and proceed to blow shop air for a minimum of 5 minutes, utilizing a very slow sweeping action. 6. Blow the entire core face with an up and down motion, then repeat moving from side to side. NOTE ATTENTION TO THE BLOW-OFF OF THE EVAPORATOR CORE SURFACE WILL DETERMINE EFFECTIVENESS OF REPAIR. 7. Install the blower motor per WSM, Section 412. 8. Open all registers. 9. Operate the A/C system in Max mode with the blower on the lowest setting. Monitor the temperature with a thermometer until the lowest temp is achieved. Switch to vent and monitor the temperature until ambient temperature is reached. 10. Repeat Step 9 three (3) additional times. 11. Switch the blower motor to high speed with the vent mode still selected. white flakes should not come out of the vents. If no white flakes are present continue to Step 12. 12. Disconnect vacuum cleaner and remove tape from floor duct. 13. Reassemble floor duct trim. 14. Blow powder off or vacuum dash board and vehicle interior as required. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > Customer Interest for Air Duct: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 7608 OPERATION DESCRIPTION TIME 092106A 2004-2005 F-150, 1.2 Hrs. 2008-2010 Crown Victoria, Grand Marquis, Escape, Escape Hybrid, Mariner, Mariner Hybrid, 2005-2009 Focus, 2007-2009 Edge, MKX: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) 092106A 2000-2005 Expedition, 1.4 Hrs. Navigator, 2008-2010 Town Car, 2000-2003 F-150: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19860 49 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Duct: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents Air Duct: All Technical Service Bulletins A/C - White Flakes Are Blowing From Dash Vents TSB 09-21-6 11/02/09 WHITE FLAKES COMING FROM A/C VENTS FORD: 2005-2009 Focus 2008-2010 Crown Victoria 2000-2005 Expedition, F-150 2007-2009 Edge 2008-2010 Escape Hybrid, Escape LINCOLN: 2008-2010 Town Car 2000-2005 Navigator 2007-2009 MKX MERCURY: 2008-2010 Grand Marquis, Mariner Hybrid, Mariner This article supersedes TSB 9-19-16 to update the Service Procedure. ISSUE Some vehicles may experience white flakes coming from the A/C vents when the blower motor is engaged. This may be caused by flux utilized in the manufacturing process of the evaporator core. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Hazard and Risk Warnings for White Flakes WARNING MAY CAUSE EYE AND RESPIRATORY TRACT IRRITATION. PROLONGED REPEATED EXPOSURE MAY CAUSE BONE DAMAGE (FLUOROSIS) AND HARM TO THE RESPIRATORY SYSTEM (BASED ON ANIMAL DATA). ^ Avoid inhaling dust. ^ Avoid contact with eyes. ^ Store away from acids. ^ Wash thoroughly after handling. ^ Avoid release to the environment. NOTE THE USE OF DUST PROOF GOGGLES, CHEMICAL RESISTANT GLOVES (PVC) AND DUST MASK IS RECOMMENDED. Using compressed air (maximum inlet pressure) 100 PSI (689 kPa), clean the A/C ducts through the registers and blow off the evaporator core through the blower motor opening. NOTE THE ENTIRE EVAPORATOR CORE SURFACE MUST BE DRY FOR BEST RESULTS. NOTE WHILE PERFORMING THIS PROCEDURE AND SELECTING DIFFERENT VENT MODES SUCH AS FLOOR / PANEL AND FLOOR / DEFROST, IT MAY BE NECESSARY TO TEMPORARILY START THE ENGINE TO ENABLE MODE DOOR MOVEMENT. Clean A/C Ducts: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Duct: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 7614 1. Remove floor duct trim. 2. Using masking tape, connect one end of the vacuum cleaner hose to the floor duct on driver side. 3. Tape closed all the other floor duct openings. 4. Obtain about two feet (61 cm) of rubber vacuum line large enough to fit the end of a small shop air blowgun. Secure the hose to the end of the blowgun using a worm clamp. 5. Close all instrument panel registers. 6. Set temperature setting to full cold. 7. Place mode in floor / panel. 8. Turn on vacuum cleaner. 9. Working with one register at a time insert the vacuum line down each duct and blow shop air through each duct for 30 seconds. Be sure to close each register before moving on to the next register. 10. Change mode to floor I defrost. 11. Blow down each defroster duct for 30 seconds. 12. Alternate mode door between floor and floor / defrost three (3) times, giving the door time to move between each change. 13. Turn off vacuum cleaner. Clean Evaporator Core: 1. Change mode to full floor. 2. Ensure temperature is full cold. 3. Remove blower motor per Workshop Manual (WSM), Section 412. 4. Turn on vacuum cleaner. 5. Reach into blower opening with vacuum line and proceed to blow shop air for a minimum of 5 minutes, utilizing a very slow sweeping action. 6. Blow the entire core face with an up and down motion, then repeat moving from side to side. NOTE ATTENTION TO THE BLOW-OFF OF THE EVAPORATOR CORE SURFACE WILL DETERMINE EFFECTIVENESS OF REPAIR. 7. Install the blower motor per WSM, Section 412. 8. Open all registers. 9. Operate the A/C system in Max mode with the blower on the lowest setting. Monitor the temperature with a thermometer until the lowest temp is achieved. Switch to vent and monitor the temperature until ambient temperature is reached. 10. Repeat Step 9 three (3) additional times. 11. Switch the blower motor to high speed with the vent mode still selected. white flakes should not come out of the vents. If no white flakes are present continue to Step 12. 12. Disconnect vacuum cleaner and remove tape from floor duct. 13. Reassemble floor duct trim. 14. Blow powder off or vacuum dash board and vehicle interior as required. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Duct: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 7615 OPERATION DESCRIPTION TIME 092106A 2004-2005 F-150, 1.2 Hrs. 2008-2010 Crown Victoria, Grand Marquis, Escape, Escape Hybrid, Mariner, Mariner Hybrid, 2005-2009 Focus, 2007-2009 Edge, MKX: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) 092106A 2000-2005 Expedition, 1.4 Hrs. Navigator, 2008-2010 Town Car, 2000-2003 F-150: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19860 49 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > Page 7616 Air Duct: Specifications LH instrument panel brace nut 7 Nm RH instrument panel brace bolt 7 Nm RH instrument panel brace bolt 7 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > Page 7617 Air Duct: Locations A/C Air Distribution Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Technical Service Bulletins > Page 7618 Auxiliary A/C Air Distribution Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct Air Duct: Service and Repair Floor Duct Duct - Floor Removal and Installation 1. Remove the restraints control module. 2. Remove the nut and bolt and the RH instrument panel brace. 3. Remove the lower LH instrument panel brace nut and position the brace aside. 4. Cut the sides of the rear seat floor duct at the floor duct connection to allow it to be folded away from the floor duct. 5. Remove the floor duct. 1. Remove the 2 floor duct screws. 2. Remove the floor duct. 6. To install, reverse the removal procedure. - Install a tie strap around the end of the rear seat floor duct at the floor duct connection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor Duct > Page 7621 Air Duct: Service and Repair Rear Seat Airflow Duct REMOVAL 1. If equipped, remove the center console blower motor. Refer to: Heating and Air Conditioning, Blower Motor, Service and Repair, Blower Motor - Center Console, See: Blower Motor/Service and Repair/Blower Motor - Center Console 2. If equipped; remove the floor duct panel. ^ Remove the pin-type retainers and release the expander clip. 3. Remove the front seats. 4. Remove the kick panel and the sill trim. 5. Pull back the carpet. 6. Remove the pin-type retainers and remove the duct. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Customer Interest: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents Air Register: Customer Interest A/C - White Flakes Are Blowing From Dash Vents TSB 09-21-6 11/02/09 WHITE FLAKES COMING FROM A/C VENTS FORD: 2005-2009 Focus 2008-2010 Crown Victoria 2000-2005 Expedition, F-150 2007-2009 Edge 2008-2010 Escape Hybrid, Escape LINCOLN: 2008-2010 Town Car 2000-2005 Navigator 2007-2009 MKX MERCURY: 2008-2010 Grand Marquis, Mariner Hybrid, Mariner This article supersedes TSB 9-19-16 to update the Service Procedure. ISSUE Some vehicles may experience white flakes coming from the A/C vents when the blower motor is engaged. This may be caused by flux utilized in the manufacturing process of the evaporator core. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Hazard and Risk Warnings for White Flakes WARNING MAY CAUSE EYE AND RESPIRATORY TRACT IRRITATION. PROLONGED REPEATED EXPOSURE MAY CAUSE BONE DAMAGE (FLUOROSIS) AND HARM TO THE RESPIRATORY SYSTEM (BASED ON ANIMAL DATA). ^ Avoid inhaling dust. ^ Avoid contact with eyes. ^ Store away from acids. ^ Wash thoroughly after handling. ^ Avoid release to the environment. NOTE THE USE OF DUST PROOF GOGGLES, CHEMICAL RESISTANT GLOVES (PVC) AND DUST MASK IS RECOMMENDED. Using compressed air (maximum inlet pressure) 100 PSI (689 kPa), clean the A/C ducts through the registers and blow off the evaporator core through the blower motor opening. NOTE THE ENTIRE EVAPORATOR CORE SURFACE MUST BE DRY FOR BEST RESULTS. NOTE WHILE PERFORMING THIS PROCEDURE AND SELECTING DIFFERENT VENT MODES SUCH AS FLOOR / PANEL AND FLOOR / DEFROST, IT MAY BE NECESSARY TO TEMPORARILY START THE ENGINE TO ENABLE MODE DOOR MOVEMENT. Clean A/C Ducts: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Customer Interest: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 7630 1. Remove floor duct trim. 2. Using masking tape, connect one end of the vacuum cleaner hose to the floor duct on driver side. 3. Tape closed all the other floor duct openings. 4. Obtain about two feet (61 cm) of rubber vacuum line large enough to fit the end of a small shop air blowgun. Secure the hose to the end of the blowgun using a worm clamp. 5. Close all instrument panel registers. 6. Set temperature setting to full cold. 7. Place mode in floor / panel. 8. Turn on vacuum cleaner. 9. Working with one register at a time insert the vacuum line down each duct and blow shop air through each duct for 30 seconds. Be sure to close each register before moving on to the next register. 10. Change mode to floor I defrost. 11. Blow down each defroster duct for 30 seconds. 12. Alternate mode door between floor and floor / defrost three (3) times, giving the door time to move between each change. 13. Turn off vacuum cleaner. Clean Evaporator Core: 1. Change mode to full floor. 2. Ensure temperature is full cold. 3. Remove blower motor per Workshop Manual (WSM), Section 412. 4. Turn on vacuum cleaner. 5. Reach into blower opening with vacuum line and proceed to blow shop air for a minimum of 5 minutes, utilizing a very slow sweeping action. 6. Blow the entire core face with an up and down motion, then repeat moving from side to side. NOTE ATTENTION TO THE BLOW-OFF OF THE EVAPORATOR CORE SURFACE WILL DETERMINE EFFECTIVENESS OF REPAIR. 7. Install the blower motor per WSM, Section 412. 8. Open all registers. 9. Operate the A/C system in Max mode with the blower on the lowest setting. Monitor the temperature with a thermometer until the lowest temp is achieved. Switch to vent and monitor the temperature until ambient temperature is reached. 10. Repeat Step 9 three (3) additional times. 11. Switch the blower motor to high speed with the vent mode still selected. white flakes should not come out of the vents. If no white flakes are present continue to Step 12. 12. Disconnect vacuum cleaner and remove tape from floor duct. 13. Reassemble floor duct trim. 14. Blow powder off or vacuum dash board and vehicle interior as required. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Customer Interest: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 7631 OPERATION DESCRIPTION TIME 092106A 2004-2005 F-150, 1.2 Hrs. 2008-2010 Crown Victoria, Grand Marquis, Escape, Escape Hybrid, Mariner, Mariner Hybrid, 2005-2009 Focus, 2007-2009 Edge, MKX: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) 092106A 2000-2005 Expedition, 1.4 Hrs. Navigator, 2008-2010 Town Car, 2000-2003 F-150: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19860 49 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents Air Register: All Technical Service Bulletins A/C - White Flakes Are Blowing From Dash Vents TSB 09-21-6 11/02/09 WHITE FLAKES COMING FROM A/C VENTS FORD: 2005-2009 Focus 2008-2010 Crown Victoria 2000-2005 Expedition, F-150 2007-2009 Edge 2008-2010 Escape Hybrid, Escape LINCOLN: 2008-2010 Town Car 2000-2005 Navigator 2007-2009 MKX MERCURY: 2008-2010 Grand Marquis, Mariner Hybrid, Mariner This article supersedes TSB 9-19-16 to update the Service Procedure. ISSUE Some vehicles may experience white flakes coming from the A/C vents when the blower motor is engaged. This may be caused by flux utilized in the manufacturing process of the evaporator core. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Hazard and Risk Warnings for White Flakes WARNING MAY CAUSE EYE AND RESPIRATORY TRACT IRRITATION. PROLONGED REPEATED EXPOSURE MAY CAUSE BONE DAMAGE (FLUOROSIS) AND HARM TO THE RESPIRATORY SYSTEM (BASED ON ANIMAL DATA). ^ Avoid inhaling dust. ^ Avoid contact with eyes. ^ Store away from acids. ^ Wash thoroughly after handling. ^ Avoid release to the environment. NOTE THE USE OF DUST PROOF GOGGLES, CHEMICAL RESISTANT GLOVES (PVC) AND DUST MASK IS RECOMMENDED. Using compressed air (maximum inlet pressure) 100 PSI (689 kPa), clean the A/C ducts through the registers and blow off the evaporator core through the blower motor opening. NOTE THE ENTIRE EVAPORATOR CORE SURFACE MUST BE DRY FOR BEST RESULTS. NOTE WHILE PERFORMING THIS PROCEDURE AND SELECTING DIFFERENT VENT MODES SUCH AS FLOOR / PANEL AND FLOOR / DEFROST, IT MAY BE NECESSARY TO TEMPORARILY START THE ENGINE TO ENABLE MODE DOOR MOVEMENT. Clean A/C Ducts: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 7637 1. Remove floor duct trim. 2. Using masking tape, connect one end of the vacuum cleaner hose to the floor duct on driver side. 3. Tape closed all the other floor duct openings. 4. Obtain about two feet (61 cm) of rubber vacuum line large enough to fit the end of a small shop air blowgun. Secure the hose to the end of the blowgun using a worm clamp. 5. Close all instrument panel registers. 6. Set temperature setting to full cold. 7. Place mode in floor / panel. 8. Turn on vacuum cleaner. 9. Working with one register at a time insert the vacuum line down each duct and blow shop air through each duct for 30 seconds. Be sure to close each register before moving on to the next register. 10. Change mode to floor I defrost. 11. Blow down each defroster duct for 30 seconds. 12. Alternate mode door between floor and floor / defrost three (3) times, giving the door time to move between each change. 13. Turn off vacuum cleaner. Clean Evaporator Core: 1. Change mode to full floor. 2. Ensure temperature is full cold. 3. Remove blower motor per Workshop Manual (WSM), Section 412. 4. Turn on vacuum cleaner. 5. Reach into blower opening with vacuum line and proceed to blow shop air for a minimum of 5 minutes, utilizing a very slow sweeping action. 6. Blow the entire core face with an up and down motion, then repeat moving from side to side. NOTE ATTENTION TO THE BLOW-OFF OF THE EVAPORATOR CORE SURFACE WILL DETERMINE EFFECTIVENESS OF REPAIR. 7. Install the blower motor per WSM, Section 412. 8. Open all registers. 9. Operate the A/C system in Max mode with the blower on the lowest setting. Monitor the temperature with a thermometer until the lowest temp is achieved. Switch to vent and monitor the temperature until ambient temperature is reached. 10. Repeat Step 9 three (3) additional times. 11. Switch the blower motor to high speed with the vent mode still selected. white flakes should not come out of the vents. If no white flakes are present continue to Step 12. 12. Disconnect vacuum cleaner and remove tape from floor duct. 13. Reassemble floor duct trim. 14. Blow powder off or vacuum dash board and vehicle interior as required. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 7638 OPERATION DESCRIPTION TIME 092106A 2004-2005 F-150, 1.2 Hrs. 2008-2010 Crown Victoria, Grand Marquis, Escape, Escape Hybrid, Mariner, Mariner Hybrid, 2005-2009 Focus, 2007-2009 Edge, MKX: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) 092106A 2000-2005 Expedition, 1.4 Hrs. Navigator, 2008-2010 Town Car, 2000-2003 F-150: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19860 49 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Register: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Register: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 7644 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Register: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 7645 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Register: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 7646 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Register: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 7647 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Register: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 7648 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Register: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 7654 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Register: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 7655 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Register: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 7656 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Register: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 7657 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Register: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 7658 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Page 7659 Auxiliary A/C Air Distribution Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Auxiliary Climate Control Air Register: Service and Repair Auxiliary Climate Control REMOVAL 1. Fabricate a removal tool from a 1/8-inch diameter rod. 2. Rotate the A/C register with the removal tool to align the retaining ears with the clearance openings and remove the A/C register. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Auxiliary Climate Control > Page 7662 Air Register: Service and Repair Main Climate Control LH REMOVAL 1. Remove the steering column cover panel. 2. Remove the headlamp switch. For additional information, refer to Lighting and Horns. 3. Remove the LH instrument panel finish panel. 1 Remove the eight screws. 2 Remove the instrument panel finish panel. 4. Remove the LH panel register. 1 Remove the screws. 2 Pry back the lock tabs. 3 Remove the LH panel register. INSTALLATION 1. To install, reverse the removal procedure. Center REMOVAL Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Auxiliary Climate Control > Page 7663 1. Remove the center instrument panel finish panel. 2. If equipped, disconnect the transfer case rotary control switch electrical connector. 3. Remove the center panel register(s). 1 Remove the screws. 2 Pry back the lock tabs. 3 Remove the panel register. INSTALLATION 1. To install, reverse the removal procedure. RH REMOVAL 1. Remove the instrument panel. For additional information, refer to Dash Board. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Auxiliary Climate Control > Page 7664 2. Remove the RH panel register. 1 Remove the screws. 2 Remove the RH panel register. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Ambient Temperature Sensor / Switch HVAC: Specifications Ambient Air Sensor Bracket Bolt 9 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 7668 Ambient Temperature Sensor / Switch HVAC: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 7669 Electronic Automatic Temperature Control Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 7670 Ambient Temperature Sensor / Switch HVAC: Description and Operation The A/C ambient air temperature sensor and bracket: ^ is located in front of the A/C condenser core near the center of the vehicle. ^ contains a thermistor which measures the temperature of outside air as a resistance and sends that reading to the EATC module. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 7671 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Remove the pin-type retainers and remove the radiator sight shield. 2. Disconnect the connector. 3. Remove the bolt and remove the ambient air temperature sensor panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Aspirator: > 00-1-8 > Jan > 00 > A/C - Blower Motor Stays on HIGH Aspirator: Customer Interest A/C - Blower Motor Stays on HIGH Article No. 00-1-8 1/10/00 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH SPEED AFTER DESIRED TEMPERATURE HAS BEEN REACHED - EATC EQUIPPED VEHICLES ONLY ^ AIR CONDITIONING - SYSTEM DOES NOT MAINTAIN SET TEMPERATURE - EATC EQUIPPED VEHICLES ONLY FORD: 1997-2000 EXPEDITION LINCOLN: 1998-2000 NAVIGATOR ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), the blower motor may stay on high after desired temperature is reached and/or the system does not maintain set temperature. ACTION Check for proper connection of the in-car temperature aspirator tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Cut a piece of toilet paper or tissue paper about 3.7x3.7 cm (1.5x1.5") (paper towel will not work). 2. Turn the key on and turn fan speed to HIGH. 3. Select PANEL or VENT mode. 4. Place the piece of tissue paper over the aspirator grille opening in the bezel. If aspiration (suction) is present, the tissue paper should stick to the aspirator grille. 5. Turn the fan OFF. The tissue paper should fall off. 6. If the tissue paper falls off the aspirator grille while the fan is on HIGH, check that the aspirator tube is properly connected at the right bottom corner of the front heater. The black connector on the white flexible tube should be snapped over the black tube connected to the heater plenum. Also, check for kinks and cuts in the aspirator tube. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204100, 205000, 208000, 208200, 208300, 208999 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Aspirator: > 00-1-8 > Jan > 00 > A/C - Blower Motor Stays on HIGH Aspirator: All Technical Service Bulletins A/C - Blower Motor Stays on HIGH Article No. 00-1-8 1/10/00 ^ AIR CONDITIONING - BLOWER MOTOR STAYS ON HIGH SPEED AFTER DESIRED TEMPERATURE HAS BEEN REACHED - EATC EQUIPPED VEHICLES ONLY ^ AIR CONDITIONING - SYSTEM DOES NOT MAINTAIN SET TEMPERATURE - EATC EQUIPPED VEHICLES ONLY FORD: 1997-2000 EXPEDITION LINCOLN: 1998-2000 NAVIGATOR ISSUE On some vehicles equipped with Electronic Automatic Temperature Control (EATC), the blower motor may stay on high after desired temperature is reached and/or the system does not maintain set temperature. ACTION Check for proper connection of the in-car temperature aspirator tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Cut a piece of toilet paper or tissue paper about 3.7x3.7 cm (1.5x1.5") (paper towel will not work). 2. Turn the key on and turn fan speed to HIGH. 3. Select PANEL or VENT mode. 4. Place the piece of tissue paper over the aspirator grille opening in the bezel. If aspiration (suction) is present, the tissue paper should stick to the aspirator grille. 5. Turn the fan OFF. The tissue paper should fall off. 6. If the tissue paper falls off the aspirator grille while the fan is on HIGH, check that the aspirator tube is properly connected at the right bottom corner of the front heater. The black connector on the white flexible tube should be snapped over the black tube connected to the heater plenum. Also, check for kinks and cuts in the aspirator tube. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204100, 205000, 208000, 208200, 208300, 208999 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Specifications Blower Motor: Specifications Blower Motor Screws - Plenum 2 - 3.5 Nm Blower Motor Cover Screws - Plenum 1 - 2 Nm Blower Motor Nuts - Console 2.1 - 2.9 Nm Blower Motor Cover Screws - Console 2.1 - 2.9 Nm Blower Motor Duct Screws - Console 2.1 - 2.9 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Main Climate Control Blower Motor: Locations Main Climate Control Manual A/C Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Main Climate Control > Page 7690 Electronic Automatic Temperature Control Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Main Climate Control > Page 7691 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Main Climate Control > Page 7692 Component Views Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Main Climate Control > Page 7693 Component Views Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Main Climate Control > Page 7694 Blower Motor: Locations Auxiliary Climate Control Auxiliary Climate Control An optional auxiliary air conditioning and heating system is available. The system is a one-piece unit that is located on the LH side of the vehicle between the side windows and the floorpan, behind the rear wheel well. The driver has primary control of the auxiliary air conditioning and heating system or can transfer control to a rear passenger control panel. All of the auxiliary A/C-heater system components are serviceable from the inside of the vehicle except the lines. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 7695 Blower Motor: Service Precautions CAUTION: Carefully remove the blower motor so as not to damage the wheel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Main Climate Control Blower Motor: Description and Operation Main Climate Control Blower Motor The blower motor pulls air from the air inlet and forces it into the plenum assembly where it is mixed and distributed. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Main Climate Control > Page 7698 Blower Motor: Description and Operation Auxiliary Climate Control The auxiliary air conditioning system contains a blower motor which is controlled by the heater blower motor switch on the front or rear auxiliary A/C control. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Main Climate Control Blower Motor: Service and Repair Main Climate Control REMOVAL 1. Remove the passenger side insulator panel. 2. If equipped, remove the aftermarket air filter. 3. If equipped, remove the mounting bracket for the removed cover. 4. Disconnect the christmas tree retainer from the motor mounting plate. 5. Disconnect the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Main Climate Control > Page 7701 6. Remove the blower motor cover. 1 Remove the three screws. 2 Pry to release the three tabs. 3 Remove the cover. 7. Remove the blower motor. 1 Remove the three screws. 2 Remove the blower motor. CAUTION: Carefully remove the blower motor so as not to damage the wheel. 8. Remove the wheel from the blower motor. 1 Remove the push clip. 2 Remove the wheel. 9. Remove the gasket. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Main Climate Control > Page 7702 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Main Climate Control > Page 7703 Blower Motor: Service and Repair Auxiliary Climate Control REMOVAL 1. Remove the LH quarter trim panel access cover. 2. Remove the blower motor. 1 Disconnect the electrical connector. 2 Remove the three motor cover bolts. 3 Remove the blower motor cover. 4 Remove the blower motor bolts. 5 Remove the blower motor. 3. Remove the wheel from the blower motor. 1 Remove the push clip. 2 Remove the wheel. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Main Climate Control > Page 7704 Blower Motor: Service and Repair Blower Motor - Center Console Blower Motor - Center Console REMOVAL 1. Remove the floor console. Refer to: Body and Frame, Interior Trim, Console, Service and Repair, See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair 2. Remove the floor console support braces. 1 Remove the eight screws. 2 Remove the braces. 3. Remove the blower motor duct. 1 Remove the screws. 2 Remove the duct. 4. Remove the blower motor assembly. 1 Remove the three nuts. 2 Remove the blower motor from the bottom of the console. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Main Climate Control > Page 7705 5. Disconnect the harness connectors. 6. Remove the blower motor resistor. 1 Disconnect the connector. 2 Remove the bolts. 3 Remove the resistor. 7. Remove the blower motor lower duct cover. 1 Remove the five screws. 2 Remove the duct cover. 8. Remove the blower motor upper duct cover. 1 Remove the three bolts. 2 Remove the duct cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Main Climate Control > Page 7706 9. Remove the blower motor. 1 Remove the two bolts. 2 Disconnect the connector. 3 Remove the blower motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Main Climate Control > Page 7707 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Blower Motor Relay Blower Motor Relay: Locations Blower Motor Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 7712 Located in the Blower/Flasher Relay Block, which is located behind the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 7713 Blower Motor Relay: Locations Console Blower Relay Located in the RPO Relay Block #1, which is located in the dash, above the passenger air bag. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay Blower Motor Relay: Testing and Inspection Blower Motor Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 7716 Blower Motor Relay: Testing and Inspection Console Blower Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications Blower Motor Resistor: Specifications Blower Motor Resistor Bolts 2.1 - 2.9 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications > Page 7720 Blower Motor Resistor: Locations Component Views Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications > Page 7721 Component Views Part 2 Of 2 EATC Manual Manual and EATC system: The blower motor switch resistor is located on the passenger side of the plenum assembly behind the glove compartment. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications > Page 7722 Blower Motor Resistor: Description and Operation The heater blower motor switch resistor has the following features: ^ The assembly is located on the passenger side of the plenum assembly behind the glove compartment. ^ Three resistance elements are mounted on the resistor board to provide four A/C blower motor speeds. ^ Depending on the heater blower motor switch position, series resistance is added or bypassed in the A/C blower motor circuit to decrease or increase A/C blower motor speed. ^ An overheating protective device (thermal limiter) will open the resistor coil circuit when the temperature reaches 121°C (250°F) interrupting the blower motor operation in all speeds except HI. ^ The thermal limiter cannot be reset and is not serviceable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Specifications > Page 7723 Blower Motor Resistor: Service and Repair REMOVAL 1. Remove the LH quarter trim panel access cover. 2. Disconnect the electrical connector. 3. Remove the bolts and remove the A/C blower motor resistor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Front Blower Motor Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Front Blower Motor Switch > Page 7728 Blower Motor Switch: Diagrams Rear Blower Motor Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations Cabin Temperature Sensor / Switch: Locations Component Views Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 7735 Component Views Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 7736 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 7737 Cabin Temperature Sensor / Switch: Description and Operation The in-car temperature sensor operates in the following manner: ^ A thermistor in the in-car temperature sensor measures air temperature inside the passenger compartment. ^ An automatic temperature control sensor hose and elbow is connected between the plenum assembly and the in-car temperature sensor. ^ The automatic temperature control sensor hose and elbow uses air from the plenum assembly air stream to create a suction at the in-car temperature sensor. ^ The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 7738 Cabin Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the center instrument panel finish panel. 1 Carefully pry to release the four clips. 2. If equipped, disconnect the 4WD control switch connector. 3. Remove the steering column cover panel. 4. Remove the headlamp switch. For additional information, refer to Lighting and Horns. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 7739 5. Remove the LH instrument panel finish panel. 1 Remove the screws. 2 Remove the LH instrument panel finish panel. 6. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. 7. Remove the screw. 8. Disconnect the electrical connector and remove the sensor from the hose. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair REMOVAL NOTE: The windshield wiper pivot arms must be in the highest position to remove them. 1. Turn the ignition switch to the on position. 2. Turn the windshield wiper on. 3. Stop the windshield wiper pivot arms at the highest position by turning the ignition switch off. 4. Remove the windshield wiper pivot arm. 1 Remove the pivot arm nut cover. 2 Remove the nut. 3 Remove the windshield wiper pivot arm. 5. Raise and support the hood. 6. Remove the cowl grille seal. NOTE: The two cowl grilles overlap at the center. The LH cowl grille must be removed first. 7. Remove the LH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the LH cowl grille. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service and Repair > Page 7743 8. Remove the RH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the RH cowl grille. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Adjust the pivot arms. For additional information, refer to Wiper Blade and Pivot Arm Adjustment-Windshield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications A/C Compressor FS-10 Swashplate,5 Double Acting Pistons Air Gap Between Pulley and Hub 0.35 - 0.85 mm A/C Clutch Air Gap 0.35 - 0.85 mm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7748 Compressor Clutch: Service Precautions CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7749 Compressor Clutch: Description and Operation A/C compressor and Clutch Assembly NOTE: ^ Internal A/C compressor components are not serviced separately. The FS-10 A/C compressor is serviced only as an assembly. The A/C clutch, A/C clutch pulley, A/C clutch field coil and the shaft seal are serviceable. ^ Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The FS-10 A/C compressor has the following characteristics: ^ A ten-cylinder swashplate design utilizing the tangential design mount. ^ Displacement of 170 cc (10.4 cubic inches). ^ A one-piece lip-type seal (installed from the front of the A/C compressor) is used to seal it at the shaft opening in the assembly. ^ Five double-acting pistons operate within the cylinder assembly. The pistons are actuated by a swashplate that changes the rotating action of the shaft to a reciprocating force. ^ Reed-type discharge valves are located between the cylinder assembly and the head at each end of the A/C compressor. ^ The A/C compressor uses PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C), or equivalent, meeting Ford specification WSH-M1C231-B. This oil contains special additives required for the A/C compressor. ^ The A/C compressor oil from vehicles equipped with an FS-10 A/C compressor may have a dark color while maintaining a normal oil viscosity. This is normal for this A/C compressor because carbon from the piston rings will discolor the oil. Compressor Clutch Components The magnetic A/C clutch has the following characteristics: ^ It drives the compressor shaft. ^ When battery positive voltage (B+) is applied to the A/C clutch field coil, the clutch disc and hub assembly is drawn toward the A/C clutch pulley. ^ The magnetic force locks the clutch disc and hub assembly and the A/C clutch pulley together as one unit, causing the compressor shaft to rotate. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7750 ^ When B+ is removed from the A/C clutch field coil, springs in the clutch disc and hub assembly move the clutch plate away from the A/C clutch pulley. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7751 Compressor Clutch: Adjustments 1. Check the A/C clutch air gap at three equally spaced places between the clutch hub and the A/C clutch pulley. 2. Remove the A/C clutch. Add or remove spacers between the A/C clutch and the compressor shaft until clearance is within specification. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7752 Compressor Clutch: Service and Repair SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the A/C compressor. For additional information, refer to Compressor. 2. Remove the bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7753 1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2 Remove the bolt. 3. Remove the A/C clutch and the A/C clutch hub spacer. 1 Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft. 2 Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft. 4. Remove the pulley snap ring. 5. Remove the A/C clutch pulley. 6. Remove the A/C clutch field coil. 1 Note the location of the A/C clutch field coil electrical connector. 2 Install the Field Coil Remover on the nose opening of the A/C compressor. 3 Install the Differential Bearing Cone Remover. 4 Remove the A/C clutch field coil. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7754 CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. INSTALLATION 1. Clean the A/C clutch field coil and pulley mounting surfaces. 2. Install the A/C clutch field coil. 1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector correctly positioned. 2 Place the Field Coil Replacer on the A/C clutch field coil. 3 Place the Coil Replacer on the Field Coil Replacer. 4 Use the 2-Jaw Puller to install the A/C clutch field coil until bottomed completely against the A/C compressor. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. 3. Install the A/C clutch pulley. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be correctly aligned during installation. 4. Install the pulley snap ring with the bevel side out. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7755 5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening. 6. Install the A/C clutch. 7. Install the bolt. 1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2 Tighten the bolt. 8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install the A/C compressor. For additional information, refer to Compressor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7756 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions Compressor Shaft Seal: Service Precautions CAUTION: To prevent refrigerant system contamination, do not allow dirt or other foreign materials to enter the A/C compressor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 7760 Compressor Shaft Seal: Service and Repair SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the A/C clutch from the A/C compressor. For additional information, refer to Compressor Clutch and Compressor Clutch Coil. 2. Remove the shaft seal felt from the nose of the A/C compressor with the O-ring Removal Pick. 3. Clean the compressor nose area. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 7761 4. Insert the tip of the Snap Ring Remover into one of the snap ring eyes. 5. Rotate the Snap Ring Remover to position the tool tip and the snap ring eye closest to the A/C compressor shaft. 6. Pull the Snap Ring Remover up quickly while keeping the tool shaft against the side of the nose opening and remove the snap ring. 7. Engage the Compressor Seal Remover into the inside diameter of the shaft seal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 7762 8. Turn the tool handle clockwise to expand the tool tip inside of the shaft seal. 9. Pull the seal from the A/C compressor. INSTALLATION 1. Clean the A/C compressor nose area. CAUTION: To prevent refrigerant system contamination, do not allow dirt or other foreign materials to enter the A/C compressor. 2. Place the shaft seal on the Seal Protector. Lubricate the shaft seal and the Seal Protector with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C), or equivalent, meeting Ford specification WSH-M1C231-B. 3. Position the shaft seal and the Seal Protector over the A/C compressor shaft. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 7763 4. Push the shaft seal onto the A/C compressor shaft with the Shaft Seal Installer until seated. 5. Install the shaft seal snap ring. 6. Carry out the A/C Compressor - External Leak Test. See: Testing and Inspection 7. Install the shaft seal felt. 8. Install the A/C clutch. For additional information, refer to Clutch and Clutch Field Coil. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service Precautions > Page 7764 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7768 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7769 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7770 Compressor Clutch Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications Compressor Fitting HVAC: Specifications Manifold Tube Bolt 18 - 24 Nm Manifold Tube Fitting 25.5 - 34.5 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 7774 Refrigerant System Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 7775 Compressor Fitting HVAC: Service and Repair REMOVAL 1. Perform the Refrigerant Discharging and Recovery Procedure. 2. Remove the bolt and the manifold and tube assembly. 3. Disconnect the A/C pressure cut-off switch electrical connector. 4. Disconnect the manifold and tube assembly spring lock coupling at the suction accumulator. 5. Remove the nut and disconnect the A/C condenser core inlet line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 7776 6. If equipped, remove the nut. 7. Remove the A/C pressure cut-off switch. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C), or equivalent, meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 7777 Compressor Fitting HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool (5/8 Inch) Disconnect Tool, Spring Lock Coupling Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 7778 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications Condenser HVAC: Specifications A/C Condenser Bracket Bolts 7.6 - 10.4 Nm A/C Condenser Line Nuts 6.8 - 9.2 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 7782 Condenser HVAC: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 7783 A/C Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 7784 Refrigerant System Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 7785 Condenser HVAC: Description and Operation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The A/C condenser core has the following characteristics: ^ It 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 Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 7786 Condenser HVAC: Testing and Inspection ON-VEHICLE LEAK TEST 1. Discharge and recover the refrigerant; refer to Discharging and Recovery. See: Service and Repair/Refrigerant Discharging and Recovery procedure 2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. For additional information, refer to Spring Lock Coupling. See: Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure 4. Connect the appropriate test fittings from the A/C test fitting set to the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the manifold gauge set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with 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. 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 installing a new A/C evaporator core or A/C condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. ^ If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated. ^ If a small leak is suspected, wait 30 minutes and observe the vacuum gauge. ^ If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then recheck for loss of vacuum. ^ If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for vacuum loss. 9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 7787 Condenser HVAC: Service and Repair REMOVAL NOTE: ^ Replacement of the suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. ^ If an A/C condenser core leak is suspected, the A/C condenser core must be leak tested before it is removed from the vehicle. 1. Perform the Refrigerant Discharging and Recovery Procedure. 2. Remove the radiator. For additional information, refer to Cooling System. 3. Disconnect the A/C condenser core inlet and outlet lines. 1 Remove the nuts. 2 Disconnect the A/C condenser core inlet and outlet hoses. 4. Remove the A/C condenser core. 1 Remove the bolts. 2 Remove the brackets. 3 Remove the A/C condenser core. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 7788 1. To install, reverse the removal procedure. ^ Service the new A/C condenser core with the correct amount of PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C), or equivalent, meeting Ford specification WSH-M1C231-B. See: Service and Repair/Refrigerant Oil Addition ^ Lubricate the O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C), or equivalent, meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 7789 Condenser HVAC: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Heater Hose Disconnect Tool Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 7790 Special Tool(s) Set, A/C Fittings Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Specifications Control Assembly: Specifications Auxiliary Air Conditioning And Heater assembly Bolts 6 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Specifications > Page 7794 Control Assembly: Locations Manual A/C Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Specifications > Page 7795 Component Views Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Specifications > Page 7796 Component Views Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Specifications > Page 7797 Control Assembly: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Specifications > Page 7798 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Specifications > Page 7799 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Main Climate Control Control Assembly: Description and Operation Main Climate Control The climate control assembly has three system controls: ^ The A/C heater function selector switch combines a vacuum selector valve with two electrical switches to supply battery positive voltage (B+) to the A/C clutch circuit and the blower motor control circuit. ^ The temperature selection is accomplished with a potentiometer connected to the electric blend door actuator that controls positioning of the temperature blend door. Movement of the control knob from COOL (blue) to WARM (red) causes a corresponding movement on the air temperature control door and determines the temperature that the system will maintain. ^ The blower motor switch controls blower motor speed by adding or bypassing resistors in the heater blower motor switch resistor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Main Climate Control > Page 7802 Control Assembly: Description and Operation Auxiliary Climate Control The auxiliary A/C system has dual controls for the driver and rear passengers consisting of temperature, blower speed, and mode. The front auxiliary A/C control is mounted in the overhead console or the front floor console. The rear auxiliary A/C control is mounted in a separate overhead console positioned on the roof trim panel or the rear of the front floor console. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Page 7803 Control Assembly: Testing and Inspection For further information regarding this component please refer to : Heating and Air Conditioning; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control Control Assembly: Service and Repair Auxiliary Climate Control Rear REMOVAL 1. Remove the console finish rear panel. 1 Open the cupholder. 2 Remove the four screws. 3 Disengage the retaining clips and remove the finish panel. 2. Remove the auxiliary climate control assembly. 1 Disconnect the electrical connectors. 2 Remove the screws. INSTALLATION 1. To install, reverse the removal procedure. Front REMOVAL 1. Remove the console center finish panel mat. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 7806 2. Remove the console center finish panel. 1 Remove the screw. 2 Disengage the retaining clips and remove the finish panel. 3. Remove the auxiliary climate control assembly. 1 Disconnect the electrical connectors. 2 Remove the screws. INSTALLATION 1. To install, reverse the removal procedure. Rear REMOVAL 1. Remove the auxiliary climate control assembly. 1 Slide the assembly forward and downward. 2 Disconnect the electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 7807 2. Remove the auxiliary climate control assembly from the bezel. 1 Disconnect the electrical connectors. 2 Remove the screws. 3 Remove the climate control assembly. INSTALLATION 1. To install, reverse the removal procedure. Front REMOVAL 1. Remove the overhead console. 1 Remove the screw. 2 Carefully release the three clips and slide the overhead console forward. 3 Disconnect the electrical connectors. 2. Remove the auxiliary climate control assembly from the bezel. 1 Disconnect the electrical connectors. 2 Remove the screws. 3 Remove the climate control assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 7808 Control Assembly: Service and Repair With Electronic Automatic Temperature Control REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the center instrument panel finish panel. ^ Carefully pry to release the four clips. 3. If equipped, disconnect the 4WD control switch connector. 4. Remove the climate control head. 1 Remove the screws. 2 Pull out the climate control head. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 7809 5. Disconnect the climate control head. 1 Disconnect the electrical connectors. 2 Disconnect the vacuum line connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 7810 Control Assembly: Service and Repair Control Assembly Bulbs REMOVAL 1. Remove the control assembly. For additional information, refer to Control Assembly-Electronic Automatic Temperature Control. 2. Unsnap the bezel and pivot it open. ^ To replace the general illumination bulbs, unscrew the lamp holders and remove the bulb. ^ To replace the HI/LO bulb, cut the wires close to the bulb base, splice the wires to the new bulb and wrap the splice with electrical tape. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 7811 Control Assembly: Service and Repair With Manual Climate Control REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the center instrument panel finish panel. ^ Carefully pry to release the four clips. 3. If equipped, disconnect the 4WD control switch connector. 4. Remove the screws from the Electronic Automatic Temperature Control (EATC) module. 5. Remove the EATC module. 1 Disconnect the electrical connectors. 2 Remove the nuts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 7812 3 Disconnect the vacuum harness connector and remove the EATC module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module Control Module HVAC: Locations Electronic Climate Control Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 7817 Component Views Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 7818 Component Views Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 7819 Electronic Automatic Temperature Control Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module Control Module HVAC: Diagrams Electronic Climate Control Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module > Page 7822 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module > Page 7823 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Page 7824 Control Module HVAC: Description and Operation The A/C blower motor speed control is a Pulse Width Modulated (PWM) type which provides variable blower speed control of the blower motor. The A/C blower motor speed control is controlled by switching the control signal voltage of 5 volts OFF and ON 2,000 times per second. By varying the ratio of time on (+5 volts) to time off (0 volts), the EATC module tells the A/C blower motor speed control how fast the blower motor should run. The A/C blower motor speed control has the following features: ^ Has circuitry to protect the blower motor from burning out in the event of a locked rotor condition. ^ Can compensate for changes in battery positive voltage (B+) which prevents the blower speed from slowing down when the engine is idling and will provide up to a maximum of 30 amperes for blower motor operation with battery voltages between 10 and 16 volts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Page 7825 Control Module HVAC: Service and Repair REMOVAL 1. Disengage the stops and lower the glove compartment door. 2. Remove the kickpad. 3. Disengage the aspirator hose from the bracket. NOTE: Part shown out of vehicle position. 4. Disengage the blower motor speed control mounting bracket from the instrument panel. 5. Disconnect the connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Page 7826 6. Disengage the retaining tabs and remove the blower motor speed control from the mounting bracket. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Peanut Fitting Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Peanut Fitting > Page 7831 Spring Lock Coupling Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Page 7832 Coupler HVAC: Service Precautions CAUTION: ^ Do not use metal tools to remove the O-ring seals. They can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. ^ Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring; this can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. ^ Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. ^ Use only new green O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Page 7833 Coupler HVAC: Description and Operation Spring Lock Coupling The spring lock coupling is a refrigerant line coupling held together by a garter spring inside a circular cage. ^ When the coupling is connected together, the flared end of the female fitting slips behind the garter spring inside the cage of the male fitting. ^ The garter spring and cage then prevent the flared end of the female fitting from pulling out of the cage. ^ Three O-ring seals are used to seal between the two halves of the A/C condenser core couplings, all other couplings have two O-ring seals. ^ These O-ring seals are green in color and are made of special material. ^ Use only the green O-ring seals listed in the Ford Master Parts Catalog for the spring lock coupling. ^ A plastic indicator ring is used on the spring lock couplings of the A/C evaporator core to indicate, during vehicle assembly, that the coupling is connected. Once the coupling is connected, the indicator ring is no longer necessary but will remain captive by the coupling near the cage opening. ^ The indicator ring may also be used during service operations to indicate connection of the coupling. ^ An A/C tube lock coupling clip may be used to secure the coupling but is not required. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure Coupler HVAC: Service and Repair Spring Lock Coupling Connect and Disconnect Procedure Spring Lock Coupling SPECIAL SERVICE TOOL(S) DISCONNECT 1. Perform the Refrigerant Discharging and Recovery Procedure. See: Service and Repair/Refrigerant Discharging and Recovery procedure 2. Remove the A/C tube lock coupling clip. 3. Using the special tool, disengage the spring lock coupling fittings. 4. Remove the O-ring seals with a non-metallic tool. CAUTION: Do not use metal tools to remove the O-ring seals. They can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 7836 5. Remove the A/C tube lock coupling spring with a small hooked wire. CAUTION: Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring; this can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. CLEANING 1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod. 2. Cut an abrasive pad from maroon colored 3M Scotch Brite(R) with the dimensions corresponding to the coupling size. 3. Assemble the pad to the tool. 4. Coat the abrasive pad with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 5. Roll the pad on the tool and install it in a variable speed motor drill. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 7837 6. Polish for one minute at moderate speed (less than 1,500 rpm) or until the surface is clean and free of scratches or foreign material. CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. 7. Clean the fitting with a lint-free cloth. 8. Inspect the surface for grooves or scratches. If grooves or scratches are still present, install a new component. 9. Clean the O-ring seal grooves with a 300 mm (12 inch) length of natural fiber string. ^ Loop the string around the grooves and pull the string back and forth. 10. Remove any foreign material from the grooves with a lint-free cloth. CONNECT 1. Install the A/C tube lock coupling spring. 2. Lubricate the inside of the coupling with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 7838 3. Install the O-ring seals. 1 Lubricate the O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. CAUTI0N: Use only new green O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. NOTE: Some connections may have two or three O-ring seals. 4. Connect the spring lock coupling fittings with a twisting motion until the A/C tube lock coupling spring snaps over the flared end of the female fitting. 5. Install the A/C tube lock coupling clip. 6. Charge the system. Refer to Evacuation and Charging. See: Service and Repair/Evacuation and Charging Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 7839 Coupler HVAC: Service and Repair Peanut Fitting Connect and Disconnect Procedure DISCONNECT 1. Perform the Refrigerant Discharging and Recovery Procedure. See: Service and Repair/Refrigerant Discharging and Recovery procedure 2. Remove the nut from the peanut fitting. CAUTION: Support the female fitting with a wrench to prevent the tubes from twisting. 3. Pull the peanut fitting apart. 4. Remove the O-ring seal with a non-metallic tool. CAUTION: Do not use metal tools to remove the O-ring seal. They can cause axial scratches across the O-ring seal groove resulting in refrigerant leaks. CONNECT 1. Clean all dirt or foreign material from the fittings. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Spring Lock Coupling Connect and Disconnect Procedure > Page 7840 2. Install the O-ring seal. 1 Lubricate the O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. CAUTION: Use only new purple O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. 3. Lubricate the inside of the fittings with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 4. Assemble the male and female fittings together. NOTE: When correctly assembled, the male and female fittings should be flush. 5. Charge the system. Refer to Evacuation and Charging. See: Service and Repair/Evacuation and Charging Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Specifications Evaporator Case: Specifications Auxiliary Air Conditioning And Heater assembly Bolts 6 Nm Outlet Line To Auxiliary Evaporator Case line 8 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Auxiliary Climate Control Evaporator Case: Service and Repair Auxiliary Climate Control REMOVAL 1. Perform the Refrigerant Discharging and Recovery Procedure. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Discharging and Recovery Procedure, See: Service and Repair/Refrigerant Discharging and Recovery procedure 2. Drain the engine cooling system. 3. Remove the LH quarter trim panel. 4. Disconnect the electrical connectors. 5. Disconnect the heater core hose couplings. 6. Remove the evaporator case drain hose. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Auxiliary Climate Control > Page 7846 7. Disconnect the auxiliary A/C evaporator lines. 8. Remove the A/C outlet duct. 1 Remove the pin-type retainer. 2 Remove the A/C outlet duct. 9. Remove the auxiliary air conditioning and heater assembly. 1 Remove the three bolts. 2 Remove the auxiliary air conditioning and heater assembly. INSTALLATION 1. To install, reverse the removal procedure. 2. Perform the Evacuation and Charging Procedure. Refer to: Heating and Air Conditioning, Service and Repair, Evacuation and Charging Procedure, See: Service and Repair/Evacuation and Charging Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 7847 Evaporator Case: Tools and Equipment Heater Hose Disconnect Tool Spring Lock Coupling Disconnect Tool (5/8 Inch) Disconnect Tool, Spring Lock Coupling Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 7848 Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents Evaporator Core: Customer Interest A/C - White Flakes Are Blowing From Dash Vents TSB 09-21-6 11/02/09 WHITE FLAKES COMING FROM A/C VENTS FORD: 2005-2009 Focus 2008-2010 Crown Victoria 2000-2005 Expedition, F-150 2007-2009 Edge 2008-2010 Escape Hybrid, Escape LINCOLN: 2008-2010 Town Car 2000-2005 Navigator 2007-2009 MKX MERCURY: 2008-2010 Grand Marquis, Mariner Hybrid, Mariner This article supersedes TSB 9-19-16 to update the Service Procedure. ISSUE Some vehicles may experience white flakes coming from the A/C vents when the blower motor is engaged. This may be caused by flux utilized in the manufacturing process of the evaporator core. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Hazard and Risk Warnings for White Flakes WARNING MAY CAUSE EYE AND RESPIRATORY TRACT IRRITATION. PROLONGED REPEATED EXPOSURE MAY CAUSE BONE DAMAGE (FLUOROSIS) AND HARM TO THE RESPIRATORY SYSTEM (BASED ON ANIMAL DATA). ^ Avoid inhaling dust. ^ Avoid contact with eyes. ^ Store away from acids. ^ Wash thoroughly after handling. ^ Avoid release to the environment. NOTE THE USE OF DUST PROOF GOGGLES, CHEMICAL RESISTANT GLOVES (PVC) AND DUST MASK IS RECOMMENDED. Using compressed air (maximum inlet pressure) 100 PSI (689 kPa), clean the A/C ducts through the registers and blow off the evaporator core through the blower motor opening. NOTE THE ENTIRE EVAPORATOR CORE SURFACE MUST BE DRY FOR BEST RESULTS. NOTE WHILE PERFORMING THIS PROCEDURE AND SELECTING DIFFERENT VENT MODES SUCH AS FLOOR / PANEL AND FLOOR / DEFROST, IT MAY BE NECESSARY TO TEMPORARILY START THE ENGINE TO ENABLE MODE DOOR MOVEMENT. Clean A/C Ducts: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 7857 1. Remove floor duct trim. 2. Using masking tape, connect one end of the vacuum cleaner hose to the floor duct on driver side. 3. Tape closed all the other floor duct openings. 4. Obtain about two feet (61 cm) of rubber vacuum line large enough to fit the end of a small shop air blowgun. Secure the hose to the end of the blowgun using a worm clamp. 5. Close all instrument panel registers. 6. Set temperature setting to full cold. 7. Place mode in floor / panel. 8. Turn on vacuum cleaner. 9. Working with one register at a time insert the vacuum line down each duct and blow shop air through each duct for 30 seconds. Be sure to close each register before moving on to the next register. 10. Change mode to floor I defrost. 11. Blow down each defroster duct for 30 seconds. 12. Alternate mode door between floor and floor / defrost three (3) times, giving the door time to move between each change. 13. Turn off vacuum cleaner. Clean Evaporator Core: 1. Change mode to full floor. 2. Ensure temperature is full cold. 3. Remove blower motor per Workshop Manual (WSM), Section 412. 4. Turn on vacuum cleaner. 5. Reach into blower opening with vacuum line and proceed to blow shop air for a minimum of 5 minutes, utilizing a very slow sweeping action. 6. Blow the entire core face with an up and down motion, then repeat moving from side to side. NOTE ATTENTION TO THE BLOW-OFF OF THE EVAPORATOR CORE SURFACE WILL DETERMINE EFFECTIVENESS OF REPAIR. 7. Install the blower motor per WSM, Section 412. 8. Open all registers. 9. Operate the A/C system in Max mode with the blower on the lowest setting. Monitor the temperature with a thermometer until the lowest temp is achieved. Switch to vent and monitor the temperature until ambient temperature is reached. 10. Repeat Step 9 three (3) additional times. 11. Switch the blower motor to high speed with the vent mode still selected. white flakes should not come out of the vents. If no white flakes are present continue to Step 12. 12. Disconnect vacuum cleaner and remove tape from floor duct. 13. Reassemble floor duct trim. 14. Blow powder off or vacuum dash board and vehicle interior as required. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 7858 OPERATION DESCRIPTION TIME 092106A 2004-2005 F-150, 1.2 Hrs. 2008-2010 Crown Victoria, Grand Marquis, Escape, Escape Hybrid, Mariner, Mariner Hybrid, 2005-2009 Focus, 2007-2009 Edge, MKX: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) 092106A 2000-2005 Expedition, 1.4 Hrs. Navigator, 2008-2010 Town Car, 2000-2003 F-150: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19860 49 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents Evaporator Core: All Technical Service Bulletins A/C - White Flakes Are Blowing From Dash Vents TSB 09-21-6 11/02/09 WHITE FLAKES COMING FROM A/C VENTS FORD: 2005-2009 Focus 2008-2010 Crown Victoria 2000-2005 Expedition, F-150 2007-2009 Edge 2008-2010 Escape Hybrid, Escape LINCOLN: 2008-2010 Town Car 2000-2005 Navigator 2007-2009 MKX MERCURY: 2008-2010 Grand Marquis, Mariner Hybrid, Mariner This article supersedes TSB 9-19-16 to update the Service Procedure. ISSUE Some vehicles may experience white flakes coming from the A/C vents when the blower motor is engaged. This may be caused by flux utilized in the manufacturing process of the evaporator core. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Hazard and Risk Warnings for White Flakes WARNING MAY CAUSE EYE AND RESPIRATORY TRACT IRRITATION. PROLONGED REPEATED EXPOSURE MAY CAUSE BONE DAMAGE (FLUOROSIS) AND HARM TO THE RESPIRATORY SYSTEM (BASED ON ANIMAL DATA). ^ Avoid inhaling dust. ^ Avoid contact with eyes. ^ Store away from acids. ^ Wash thoroughly after handling. ^ Avoid release to the environment. NOTE THE USE OF DUST PROOF GOGGLES, CHEMICAL RESISTANT GLOVES (PVC) AND DUST MASK IS RECOMMENDED. Using compressed air (maximum inlet pressure) 100 PSI (689 kPa), clean the A/C ducts through the registers and blow off the evaporator core through the blower motor opening. NOTE THE ENTIRE EVAPORATOR CORE SURFACE MUST BE DRY FOR BEST RESULTS. NOTE WHILE PERFORMING THIS PROCEDURE AND SELECTING DIFFERENT VENT MODES SUCH AS FLOOR / PANEL AND FLOOR / DEFROST, IT MAY BE NECESSARY TO TEMPORARILY START THE ENGINE TO ENABLE MODE DOOR MOVEMENT. Clean A/C Ducts: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 7864 1. Remove floor duct trim. 2. Using masking tape, connect one end of the vacuum cleaner hose to the floor duct on driver side. 3. Tape closed all the other floor duct openings. 4. Obtain about two feet (61 cm) of rubber vacuum line large enough to fit the end of a small shop air blowgun. Secure the hose to the end of the blowgun using a worm clamp. 5. Close all instrument panel registers. 6. Set temperature setting to full cold. 7. Place mode in floor / panel. 8. Turn on vacuum cleaner. 9. Working with one register at a time insert the vacuum line down each duct and blow shop air through each duct for 30 seconds. Be sure to close each register before moving on to the next register. 10. Change mode to floor I defrost. 11. Blow down each defroster duct for 30 seconds. 12. Alternate mode door between floor and floor / defrost three (3) times, giving the door time to move between each change. 13. Turn off vacuum cleaner. Clean Evaporator Core: 1. Change mode to full floor. 2. Ensure temperature is full cold. 3. Remove blower motor per Workshop Manual (WSM), Section 412. 4. Turn on vacuum cleaner. 5. Reach into blower opening with vacuum line and proceed to blow shop air for a minimum of 5 minutes, utilizing a very slow sweeping action. 6. Blow the entire core face with an up and down motion, then repeat moving from side to side. NOTE ATTENTION TO THE BLOW-OFF OF THE EVAPORATOR CORE SURFACE WILL DETERMINE EFFECTIVENESS OF REPAIR. 7. Install the blower motor per WSM, Section 412. 8. Open all registers. 9. Operate the A/C system in Max mode with the blower on the lowest setting. Monitor the temperature with a thermometer until the lowest temp is achieved. Switch to vent and monitor the temperature until ambient temperature is reached. 10. Repeat Step 9 three (3) additional times. 11. Switch the blower motor to high speed with the vent mode still selected. white flakes should not come out of the vents. If no white flakes are present continue to Step 12. 12. Disconnect vacuum cleaner and remove tape from floor duct. 13. Reassemble floor duct trim. 14. Blow powder off or vacuum dash board and vehicle interior as required. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-21-6 > Nov > 09 > A/C - White Flakes Are Blowing From Dash Vents > Page 7865 OPERATION DESCRIPTION TIME 092106A 2004-2005 F-150, 1.2 Hrs. 2008-2010 Crown Victoria, Grand Marquis, Escape, Escape Hybrid, Mariner, Mariner Hybrid, 2005-2009 Focus, 2007-2009 Edge, MKX: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) 092106A 2000-2005 Expedition, 1.4 Hrs. Navigator, 2008-2010 Town Car, 2000-2003 F-150: Clean A/C Ducts And Evaporator Core (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 19860 49 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 7871 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 7877 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 7878 Evaporator Core: Specifications Junction block bracket screw 12 Nm Starter relay cable nut 8 Nm Starter relay cable ends 8 Nm A/C Evaporator To Expansion Valve Lines 12.7 - 17.3 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 7879 Evaporator Core: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 7880 A/C Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 7881 Refrigerant System Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 7882 Refrigerant Lines: Part 1 0f 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 7883 Refrigerant Lines: Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Main Climate Control Evaporator Core: Description and Operation Main Climate Control A/C Evaporator Core NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The A/C evaporator core is the plate/fin type with a unique refrigerant flow path. ^ A mixture of refrigerant and oil enters the bottom of the A/C evaporator core through the A/C evaporator core inlet tube and is routed so it flows through the partitioned first three plate/fin sections. ^ The next four plate/fin sections are partitioned to force the refrigerant to flow toward the other end of the A/C evaporator core. ^ Refrigerant then continues over to the remaining five plate/fin sections and then moves out of the A/C evaporator core through the A/C evaporator core outlet tube. ^ This S-pass flow pattern accelerates the flow of refrigerant and oil through the A/C evaporator core. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Main Climate Control > Page 7886 Evaporator Core: Description and Operation Auxiliary Climate Control The auxiliary A/C system uses a rear A/C evaporator core which operates in the same manner as the front A/C evaporator core. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 7887 Evaporator Core: Testing and Inspection ON-VEHICLE LEAK TEST 1. Discharge and recover the refrigerant; refer to Discharging and Recovery. See: Service and Repair/Refrigerant Discharging and Recovery procedure 2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. For additional information, refer to Spring Lock Coupling. See: Coupler HVAC/Service and Repair/Spring Lock Coupling Connect and Disconnect Procedure 4. Connect the appropriate test fittings from the A/C test fitting set to the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the manifold gauge set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with 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. 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 installing a new A/C evaporator core or A/C condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. ^ If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated. ^ If a small leak is suspected, wait 30 minutes and observe the vacuum gauge. ^ If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then recheck for loss of vacuum. ^ If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for vacuum loss. 9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary Climate Control Evaporator Core: Service and Repair Auxiliary Climate Control REMOVAL 1. Remove the air conditioning and heater assembly. Refer to: Heating and Air Conditioning, Evaporator Case, Service and Repair, Auxiliary Climate Control, See: Evaporator Case/Service and Repair/Auxiliary Climate Control 2. Remove the auxiliary A/C evaporator lines. 3. Remove the evaporator/heater core access cover. 1 Remove the ten bolts. 2 Remove the evaporator/heater core access cover. 4. Remove the A/C evaporator core. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary Climate Control > Page 7890 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary Climate Control > Page 7891 Evaporator Core: Service and Repair Main Climate Control REMOVAL NOTE: ^ Replacement of the suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. ^ If an A/C evaporator core leak is suspected, the A/C evaporator core must be leak tested before it is removed from the vehicle. 1. Perform the Refrigerant Discharging and Recovery Procedure. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Discharging and Recovery Procedure, See: Service and Repair/Refrigerant Discharging and Recovery procedure 2. Drain the radiator. 3. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Installation 4. Remove the junction block splash shield. 5. Disconnect the cable ends. 6. Remove the junction block bracket. 1 Disengage the connector. 2 Remove the screws. 3 Remove the junction block bracket. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary Climate Control > Page 7892 7. Disconnect the heater core hose couplings. 8. Disconnect the refrigerant line spring lock couplings from the A/C evaporator core. 9. Remove the RH A/C plenum demister adapter. 1 Remove the screw. 2 Remove the RH A/C plenum demister adapter. 10. Remove the heater core outlet bracket. 1 Remove the screws. 2 Remove the bracket. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Auxiliary Climate Control > Page 7893 11. Remove the plenum assembly top. 1 Remove the 14 screws. 2 Remove the plenum assembly top. 12. Remove the A/C evaporator core from the plenum assembly. INSTALLATION 1. To install, reverse the removal procedure. ^ Service the new A/C evaporator core with the correct amount of PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C), or equivalent, meeting Ford specification WSH-M1C231-B. See: Service and Repair/Refrigerant Oil Addition 2. Perform Evacuation and Charging Procedure. Refer to: Heating and Air Conditioning, Service and Repair, Evacuation and Charging Procedure, See: Service and Repair/Evacuation and Charging Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Page 7894 Evaporator Core: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Spring Lock Coupling Disconnect Tool Set Disconnect Tool, Spring Lock Coupling Heater Hose Disconnect Tool Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Page 7895 Special Tool(s) Set, A/C Fittings Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations Clutch Cycling Orifice Tube Type Refrigerant System Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 7899 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 7900 Expansion Block/Orifice Tube: Description and Operation A/C Evaporator Core Orifice NOTE: A new A/C evaporator core orifice should be installed whenever a new compressor is installed. The A/C evaporator core orifice has the following characteristics: ^ It is located in the A/C evaporator core inlet tube. ^ It has filter screens located on the inlet and outlet ends of the tube body. ^ The inlet filter screen acts as a strainer for the liquid refrigerant flowing through the A/C evaporator core orifice. ^ O-ring seals on the A/C evaporator core orifice prevent the high-pressure liquid refrigerant from bypassing the A/C evaporator core orifice. ^ Adjustment or service cannot be made to the A/C evaporator core orifice assembly. It must be installed as a unit. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 7901 Expansion Block/Orifice Tube: Service and Repair SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the condenser to evaporator tube. For additional information, refer to Line-Condenser to Evaporator. ^ For a fixed orifice tube, carry out Steps 2 and 3. ^ For a broken orifice tube, carry out Steps 4 and 5. 2. Engage the Fixed Orifice Tube Tool to the A/C evaporator core orifice. 3. Hold the tool T-handle stationary and rotate the tool body to remove the A/C evaporator core orifice. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 7902 4. To remove a broken A/C evaporator core orifice, screw the end of the Throttle Remover into the broken A/C evaporator core orifice. 5. Hold the tool T-handle stationary and rotate the tool body to remove the broken A/C evaporator core orifice. INSTALLATION 1. Lubricate and install the O-ring seals on the A/C evaporator core orifice. 1 Use PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C), or equivalent, meeting Ford specification WSH-M1C231-B. 2. Place the A/C evaporator core orifice into the Fixed Orifice Tube Tool. 3. Insert the A/C evaporator core orifice into the condenser to evaporator tube until seated. 4. Remove the Fixed Orifice Tube Tool. 5. Install the condenser to evaporator tube. For additional information, refer to Line-Condenser to Evaporator. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Locations > Page 7903 Expansion Block/Orifice Tube: Tools and Equipment Spring Lock Coupling Disconnect Tool Set Special Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications Expansion Valve: Specifications A/C Evaporator To Expansion Valve Lines 12.7 - 17.3 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications > Page 7907 Expansion Valve: Locations For further information regarding this component please refer to: Heating and Air Conditioning; Expansion Block/Orifice Tube. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications > Page 7908 Expansion Valve: Description and Operation An A/C evaporator expansion valve automatically regulates the flow of refrigerant into the auxiliary A/C evaporator core. It is also the dividing point in the system between low and high-pressure sides. The temperature sensing bulb measures the temperature of the refrigerant in the suction line and transmits it to the A/C evaporator expansion valve. This temperature variation regulates the refrigerant flow to the auxiliary A/C evaporator core. ^ When the bulb senses a high temperature, the A/C evaporator expansion valve opens and floods refrigerant through the auxiliary A/C evaporator core. ^ When the bulb senses a low temperature, the A/C evaporator expansion valve starts closing to shut off the refrigerant to the auxiliary A/C evaporator core. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Specifications > Page 7909 Expansion Valve: Service and Repair REMOVAL 1. Perform the Refrigerant Discharging and Recovery Procedure. 2. Remove the quarter trim panel access cover. 3. Disconnect the A/C evaporator core from the A/C evaporator expansion valve. 4. Disconnect the A/C lines and remove the thermostatic expansion valve. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7918 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7919 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7925 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7926 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 7927 Heater Core: Specifications Junction block bracket screw 12 Nm Starter relay cable nut 8 Nm Starter relay cable ends 8 Nm Heater Core Bracket Screws 1.5 - 2.5 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 7928 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 7929 Heater Core: Service Precautions WARNING: ^ CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. ^ THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Auxiliary Climate Control Heater Core: Description and Operation Auxiliary Climate Control The auxiliary A/C system uses a rear heater core which operates in the same manner as the front heater core. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Auxiliary Climate Control > Page 7932 Heater Core: Description and Operation Main Climate Control Heater Core The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer the heat to air passing through the plenum. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Page 7933 Heater Core: Testing and Inspection WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require installation of a new heater core. If a heater core leak is suspected, the heater core must be tested by following the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly. 2. Check the integrity of the heater water hose clamps. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Heater Core Plugged WARNING: THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. 1. Check to see that the engine coolant is at the proper level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot: ^ the heater core may have an air pocket. ^ the heater core may be plugged. ^ the thermostat may not be working correctly. Heater Core-Pressure Test Use the radiator/heater core pressure tester to carry out the pressure test. 1. Drain the coolant from the cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the radiator/heater core pressure tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the bench test. 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 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Page 7934 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new the heater core. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Auxiliary Climate Control Heater Core: Service and Repair Auxiliary Climate Control REMOVAL 1. Remove the air conditioning and heater assembly. Refer to: Heating and Air Conditioning, Evaporator Case, Service and Repair, Auxiliary Climate Control, See: Evaporator Case/Service and Repair/Auxiliary Climate Control 2. Remove the evaporator/heater core access cover. 1 Remove the ten bolts. 2 Remove the evaporator/heater core access cover. 3. Remove the heater core. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Auxiliary Climate Control > Page 7937 Heater Core: Service and Repair Main Climate Control REMOVAL NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 1. Disconnect the battery ground cable. 2. Drain the radiator. 3. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Installation 4. Disconnect the heater core hose couplings. 5. Remove the A/C plenum demister adapter. 1 Remove the screw. 2 Remove the A/C plenum demister adapter. 6. Disconnect the vacuum line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Auxiliary Climate Control > Page 7938 7. Remove the heater core bracket. 1 Remove the two screws. 2 Remove the bracket. 8. Remove the plenum chamber top. 1 Remove the 13 screws. 2 Remove the plenum chamber top. 9. Remove the blend door assembly from the case. 10. Remove the heater core. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Auxiliary Climate Control > Page 7939 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Specifications Heater Core Case: Specifications Plenum Assembly Nuts (Passenger Side) 4 - 6 Nm Plenum Assembly Nuts (Engine Side) 4 - 6 Nm Plenum Top Screws 1.5 - 2.5 Nm Junction block bracket screw 12 Nm Starter relay cable nut 8 Nm Starter relay cable ends 8 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Main Climate Control Heater Core Case: Service and Repair Main Climate Control REMOVAL 1. Disconnect the battery ground cable. 2. Perform the Refrigerant Discharging and Recovery Procedure. 3. Drain the radiator. 4. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Installation 5. Disconnect the heater hose couplings. 6. Disconnect the refrigerant line spring lock couplings from the A/C evaporator cores. 7. Remove the plenum chamber nuts (engine side). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Main Climate Control > Page 7945 8. Disconnect the A/C vacuum hose from the A/C vacuum check valve. 9. Remove the plenum chamber nuts (interior). 10. Remove the plenum chamber. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Service and Repair > Main Climate Control > Page 7946 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7955 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7956 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7962 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 7963 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 7964 Heater Hose: Specifications Junction block bracket screw 12 Nm Starter relay cable nut 8 Nm Starter relay cable ends 8 Nm Hose Clamp 1.6 - 2.2 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 7965 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 7966 Heater Hose Coupler Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 7967 Heater Hose: Service Precautions WARNING: THE ENGINE MUST BE OFF, FULLY COOL AND THE COOLING SYSTEM FULLY DEPRESSURIZED BEFORE ATTEMPTING TO DISCONNECT ANY HEATER WATER HOSES. FAILURE TO COMPLY WITH THIS WARNING CAN RESULT IN SERIOUS INJURY OR BURNS FROM HOT LIQUID ESCAPING OUT OF THE ENGINE COOLING SYSTEM. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 7968 Heater Hose: Description and Operation Refrigerant Lines: Part 1 0f 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 7969 Refrigerant Lines: Part 2 Of 2 The auxiliary lines are two-piece tubes that are secured to the underbody of the vehicle. New auxiliary line kits are only available with multiple-piece lines for ease of installation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control Heater Hose: Service and Repair Auxiliary Climate Control Line - Front Auxiliary Heater Outlet and Inlet Refrigerant Lines: Part 1 0f 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7972 Refrigerant Lines: Part 2 Of 2 REMOVAL NOTE: The front auxiliary heater outlet line is shown; the front auxiliary heater inlet line is similar. 1. Drain the cooling system. For additional information, refer to Cooling System. 2. Turn the air suspension switch off, if equipped. 3. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 4. Remove the wheel and tire assembly. For additional information, refer to Wheels,Tires and Alignment. 5. Loosen the RH front fender splash shield. 1 Remove the bolts. 2 Remove the pin-type retainers. 3 Move the front fender splash shield to access the lines. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7973 6. Remove the three line bracket retaining nuts. 7. Remove the three line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 8. Disconnect the heater outlet line from the outlet hose coupling. 9. Disconnect the front auxiliary heater outlet line from the rear auxiliary heater outlet line. 1 Remove the nut. 2 Disconnect the line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7974 10. Cut the heater outlet line where it crosses under the frame. 11. Cut the heater outlet line near the front wheel well opening. 12. Remove and discard the cut sections. INSTALLATIONS NOTE: Refer to the Multiple-Piece Auxiliary A/C Heater Line Kit illustration in Description and Operation. 1. Install the heater outlet line. ^ Install the end with the blue tape over the frame. 2. Connect the heater outlet line peanut fitting. 1 Connect the fitting. 2 Loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7975 3. Install the heater outlet line. ^ Install the end with the red tape over the frame. ^ Install the end with the yellow tape between the frame and the body vertical flange. NOTE: View shown with fender skirt removed for clarity. 4. Connect the heater water outlet line to the heater water outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fitting. 2 Loosely install the nut. 5. Install the heater water outlet line to the heater water outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. ^ Install the line through the wheel opening. NOTE: Fender skirt removed for clarity. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7976 6. Connect the heater water outlet line to the heater water outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fitting. 2 Loosely install the nut. 7. Tighten the three peanut fittings. 8. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: ^ Verify that clearance exists between the frame and the lines to prevent component damage. ^ Overtightening of the nut will cause the stud to break away from the floorpan. NOTE: The bracket must be positioned equally between the white location marks on the line. 9. Connect the heater water outlet line to the engine heater outlet hose coupling. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7977 10. Install the bolts, the pin-type retainers and the front fender splash shield. 11. Install the wheel and tire assembly. For additional information, refer to Wheels,Tires and Alignment. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Fill the cooling system. For additional information, refer to Cooling System. Inlet Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7978 Refrigerant Lines: Part 1 0f 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7979 Refrigerant Lines: Part 2 Of 2 REMOVAL 1. Drain the cooling system. For additional information, refer to Cooling System. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater inlet hose coupling. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7980 7. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 8. Lower the muffler heat shield. 1 Remove the two front bolts. 2 Lower the heat shield. 9. Remove the four line bracket retaining nuts. 10. Remove the four line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 11. Disconnect the inlet line peanut fitting. 1 Remove the nut. 2 Disconnect the line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7981 12. Cut the heater inlet line near the A/C line grommet. 13. Cut the heater inlet line near the rear crossmember. 14. Cut the heater inlet line between the frame and the muffler heat shield. 15. Remove and discard the cut sections. INSTALLATION NOTE: ^ Lay out new lines in vehicle position to assist in installation. ^ Refer to the Multiple-Piece Auxiliary A/C Heater Line Kit illustration in Description and Operation. 1. Install the heater inlet line. ^ Starting from the rear of the vehicle, install the end with the green tape over the rear axle between the frame crossmember and the body. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7982 2. Connect the heater inlet line peanut fitting. 1 Connect the inlet lines. 2 Loosely install the nut. 3. Install the heater inlet line. ^ Starting from the rear of the vehicle, install the end with the blue tape between the frame crossmember and the floor pan. 4. Connect the heater inlet line to the heater inlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fittings. 2 Loosely install the nut. 5. Install the heater inlet line. 1 Remove the RH rear wheel and tire. 2 Install the end with the red tape between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7983 6. Connect the heater inlet line to the heater inlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fittings. 2 Loosely install the nut. 7. Install the heater inlet line. ^ Install the end with the green tape through the floor opening. 8. Connect the heater inlet line to the heater inlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fittings. 2 Loosely install the nut. 9. Tighten the four peanut fittings. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7984 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floor pan. NOTE: The bracket must be positioned equally between the white location marks on the line. 11. Install the muffler heat shield. 1 Position the shield. 2 Install the nuts. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 15. Connect the heater inlet hose coupling. 16. Install the quarter trim access panel. 17. Install the spare tire. 18. Fill the cooling system. For additional information, refer to Cooling System. Outlet Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7985 Refrigerant Lines: Part 1 0f 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7986 Refrigerant Lines: Part 2 Of 2 REMOVAL 1. Drain the cooling system. For additional information, refer to Cooling System. 2. Remove the quarter trim panel access cover. 3. Disconnect the heater outlet hose coupling. 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7987 7. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 8. Lower the muffler heat shield. 1 Remove the two front bolts. 2 Lower the heat shield. 9. Remove the four line bracket retaining nuts. 10. Remove the four line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 11. Disconnect the outlet line peanut fitting. 1 Remove the nut. 2 Disconnect the line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7988 12. Cut the heater outlet line near the grommet. 13. Cut the heater outlet line near the rear crossmember. 14. Cut the heater outlet line between the frame and the muffler heat shield. 15. Remove and discard the cut sections. INSTALLATION NOTE: ^ Lay out new lines in vehicle position to assist in installation. ^ Refer to the Multiple-Piece Auxiliary A/C Heater Line Kit illustration in Description and Operation. 1. Install the heater outlet line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7989 ^ Starting from the rear of the vehicle, install the end with the blue tape over the axle between the frame and the body. 2. Connect the heater outlet line peanut fitting. 1 Connect the outlet lines. 2 Loosely install the nut. 3. Install the heater outlet line. ^ Starting from the rear of the vehicle, install the end with the red tape between the frame and the floor pan. 4. Connect the heater outlet line to the heater outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fittings. 2 Loosely install the nut. 5. Install the heater outlet line. 1 Remove RH rear wheel and tire. 2 Install the end with blue tape between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7990 6. Connect the heater outlet line to the heater outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fittings. 2 Loosely install the nut. 7. Install the heater outlet line. ^ Install the end with the hose through the floor opening. 8. Connect the heater outlet line to the heater outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the fittings. 2 Loosely install the nuts. 9. Tighten the four peanut fittings. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7991 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floorpan. NOTE: The bracket must be positioned equally between the white location marks on the line. 11. Install the muffler heat shield. 1 Position the shield. 2 Install the nuts. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Install the grommet seal and retainer. NOTE: Verify that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 15. Connect the heater outlet hose coupling. 16. Install the quarter trim access panel. 17. Install the spare tire. 18. Fill the cooling system. For additional information, refer to Cooling System. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7992 Heater Hose: Service and Repair Heater Hose Coupling Disconnect Procedure Heater Hose Disconnect Tool SPECIAL SERVICE TOOL(S) DISCONNECT 1. Depressurize the engine cooling system. WARNING: THE ENGINE MUST BE OFF, FULLY COOL AND THE COOLING SYSTEM FULLY DEPRESSURIZED BEFORE ATTEMPTING TO DISCONNECT ANY HEATER WATER HOSES. FAILURE TO COMPLY WITH THIS WARNING CAN RESULT IN SERIOUS INJURY OR BURNS FROM HOT LIQUID ESCAPING OUT OF THE ENGINE COOLING SYSTEM. 2. Push the heater water hose toward the tube to fully expose the locking tabs. 3. Push the Heater Hose Disconnect Set over the coupling retainer windows to compress the retainer locking tabs. NOTE: When compressing the white coupling retainer, the Heater Hose Disconnect Set must be perpendicular to and on the highest point of the coupling. 4. Pull the heater water hose away from the heater core tube. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to assist in the removal. 5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7993 7. Spread the retainer tabs apart and slide the retainer off the tube. 8. Discard the retainer. CONNECT 1. Clean the tubes and lubricate with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESF-M99B112-A. 2. Install a new coupling retainer, spacer, and lubricated O-rings into the quick disconnect coupling housing. 3. Push the heater water hose with a quick disconnect coupling onto the tube. 4. Make sure the coupling is fully engaged by lightly pulling on the heater water hose. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7994 Heater Hose: Service and Repair Heater Hose Assembly REMOVAL 1. Drain the radiator. For additional information, refer to Cooling System. 2. Disconnect the heater outlet hose at the engine. 3. Disconnect the heater inlet hose at the engine. 1 Loosen the hose clamp. 2 Disconnect the heater inlet hose. 4. Disconnect the heater core hose couplings. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Auxiliary Climate Control > Page 7995 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Page 7996 Heater Hose Disconnect And Removal Tools Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Locations High Pressure Safety Valve HVAC: Locations Clutch Cycling Orifice Tube Type Refrigerant System Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Locations > Page 8000 Refrigerant System Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Locations > Page 8001 High Pressure Safety Valve HVAC: Description and Operation A/C Compressor Pressure relief valve An A/C compressor pressure relief valve is incorporated in the compressor A/C manifold and tube to: ^ relieve unusually high refrigerant system discharge pressure buildups (3,103 kPa and above). ^ prevent damage to the A/C compressor and other system components. ^ avoid total refrigerant loss by closing after the excessive pressure has been relieved. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Hose/Line HVAC Hose/Line HVAC: Specifications Peanut Fittings 6.8 - 9.2 Nm Peanut Fitting Expansion Vallve Refrigerant Lines 8 Nm Peanut Fitting Rear Heater Lines 8 Nm A/C Line Bracket Nuts 6.8 - 9.2 Nm A/C Evaporator To Expansion Valve Lines 12.7 - 17.3 Nm Outlet Line To Auxiliary Evaporator Case Line 8 Nm Front Auxiliary Heater Line Brackets 8 Nm Front Auxiliary A/C Line Bracket 8 Nm Front fender splash shield bolts 10.2-13.8 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Hose/Line HVAC > Page 8006 Hose/Line HVAC: Specifications Refrigerant Lines To Expansion Valve 12.7 - 17.3 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 8007 Hose/Line HVAC: Locations Refrigerant Lines: Part 1 0f 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 8008 Refrigerant Lines: Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 8009 Hose/Line HVAC: Service Precautions CAUTION: ^ Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. ^ Overtightening of the nut will cause the stud to break away from the floor pan. ^ Verify that clearance exists between the frame and the lines to prevent component damage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 8010 Hose/Line HVAC: Description and Operation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. The A/C manifold and tube is attached to the A/C compressor with O-ring seals and has the following features: ^ The upstream side contains low pressure refrigerant gas. ^ The downstream side contains high pressure refrigerant gas. ^ An integral non-serviceable muffler and a serviceable high pressure A/C charge port valve are located on the downstream side. ^ The downstream side also contains a fitting used to mount the A/C pressure cutoff switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure cutoff switch can be removed without discharging the A/C system. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control Hose/Line HVAC: Service and Repair Auxiliary Climate Control Front Auxiliary Evaporator Outlet and Inlet Line REMOVAL NOTE: The 5/8 inch front auxiliary evaporator outlet line is shown, the 3/8 inch front auxiliary evaporator inlet line is similar. 1. Recover the refrigerant from the system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Discharging and Recovery Procedure, See: Service and Repair/Refrigerant Discharging and Recovery procedure 2. Turn the air suspension switch off, if equipped. 3. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 5. Remove the RH front fender splash shield. 1 Remove the bolts. 2 Remove the pin-type retainers. 3 Remove the front fender splash shield. 6. Remove the three line bracket retaining nuts. 7. Remove the three line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8013 8. Disconnect the 5/8 inch auxiliary outlet line from the suction side of the A/C manifold and tube assembly. 1 Remove the nut. 2 Disconnect the line. 9. Disconnect the front auxiliary outlet line from the rear auxiliary line. 1 Remove the nut. 2 Disconnect the line. 10. Remove the front auxiliary evaporator outlet line. INSTALLATION 1. Install the front auxiliary evaporator outlet line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8014 2. Connect the front auxiliary outlet line to the rear auxiliary line. 1 Connect the outlet lines. 2 Loosely install the nut. 3 Snap the peanut fitting securely into the torque retention bracket. 3. Connect the front auxiliary outlet line to the suction side of the A/C manifold and tube assembly. 1 Connect the line. 2 Install the nut. 4. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floor pan. NOTE: The bracket must be positioned equally between the white location marks on the line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8015 5. Install the bolts, the pin-type retainers and the front fender splash shield. 6. Lower the vehicle. 7. Turn on the air suspension switch, if equipped. 8. Evacuate and charge the A/C system. Refer to: Heating and Air Conditioning, Service and Repair, Evacuation and Charging Procedure, See: Service and Repair/Evacuation and Charging Procedure Rear Auxiliary Evaporator Inlet Line Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8016 Refrigerant Lines: Part 1 0f 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8017 Refrigerant Lines: Part 2 Of 2 REMOVAL 1. Perform the Refrigerant Discharging and Recovery Procedure. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Discharging and Recovery Procedure, See: Service and Repair/Refrigerant Discharging and Recovery procedure 2. Remove the quarter trim panel access cover. 3. Disconnect the inlet line from the underbody line. 1 Remove the nut. 2 Remove the line. 4. Remove the auxiliary A/C lines grommet retainer. 1 Remove the bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8018 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 8. Remove the four line bracket retaining nuts. 9. Remove the four line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 10. Disconnect the inlet line peanut fitting. 1 Remove the nut. 2 Disconnect the line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8019 11. Cut the 3/8 inch evaporator inlet line near the A/C line grommet. 12. Cut the 3/8 inch evaporator inlet line near the rear crossmember. 13. Cut the 3/8 inch evaporator inlet line forward of the rear wheel opening. 14. Cut the 3/8 inch evaporator inlet line between the frame and the muffler heat shield. 15. Remove and discard the cut sections. INSTALLATION NOTE: Lay out new lines in vehicle position to assist in installation. 1. Install the inlet line. ^ Install the end with the hose over the rear axle between the frame and the body. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8020 NOTE: Refer to the Multiple-Piece Auxiliary A/C Heater Line Kit illustration in Description and Operation. 2. Connect the inlet line peanut fitting. 1 Connect the inlet lines. 2 Loosely install the nut. 3 Snap the peanut fitting into the torque retention bracket. 3. Install the inlet line. ^ Starting from the rear of the vehicle, insert the end with the orange tape between the frame and the body. 4. Connect the inlet line to the inlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the inlet lines. 2 Loosely install the nut. 5. Install the inlet line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8021 1 Remove the RH rear wheel and tire. 2 Install the end with the yellow tape between the frame and the body. 6. Connect the inlet line to the inlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. ^ Connect the fitting and loosely install the nut. 7. Install the inlet line. ^ Install the end without tape through the floor. 8. Connect the inlet line to the inlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the line 2 Loosely install the nut. 9. Tighten the four peanut fittings. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8022 10. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floor pan. NOTE: The bracket must be positioned equally between the white location marks on the line. 11. Lower the vehicle. 12. Turn on the air suspension switch, if equipped. 13. Connect the inlet line to the auxiliary evaporator case line. 14. Install the grommet seal and retainer. NOTE: Make sure that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 15. Install the quarter trim access panel. 16. Evacuate and charge the A/C system. Refer to: Heating and Air Conditioning, Service and Repair, Evacuation and Charging Procedure, See: Service and Repair/Evacuation and Charging Procedure 17. Install the spare tire. Rear Auxiliary Evaporator Outlet Line Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8023 Refrigerant Lines: Part 1 0f 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8024 Refrigerant Lines: Part 2 Of 2 REMOVAL NOTE: Lay out new lines in vehicle position to assist in installation. 1. Perform the Refrigerant Discharging and Recovery Procedure. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Discharging and Recovery Procedure, See: Service and Repair/Refrigerant Discharging and Recovery procedure 2. Remove the quarter trim panel access cover. 3. Disconnect the outlet line from the underbody line. 1 Remove the nut. 2 Remove the line. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8025 4. Remove the auxiliary A/C line grommet retainer. 1 Remove the bolts. 2 Remove the retainer. 5. Remove the spare tire. 6. Turn the air suspension switch off, if equipped. 7. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair. 8. Lower the muffler heat shield. 1 Remove the two front nuts. 2 Lower the heat shield. 9. Remove the four line bracket retaining nuts. 10. Remove the four line brackets by inserting a screwdriver in the stud hole and twisting. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8026 CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage. 11. Disconnect the 5/8 inch outlet line peanut fitting that is located outboard of the side rail. 1 Remove the nut. 2 Disconnect the line. 12. Cut the 5/8 inch evaporator outlet line near the A/C line grommet. 13. Cut the 5/8 inch evaporator outlet line near the rear crossmember. 14. Cut the 5/8 inch evaporator outlet line forward of the rear wheel opening. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8027 15 Cut the 5/8 inch evaporator outlet line between the frame and the muffler heat shield. 16 Remove and discard the cut sections. INSTALLATION NOTE: ^ Lay out new lines in vehicle position to assist in installation. ^ Refer to the Multiple-Piece Auxiliary A/C Heater Line Kit illustration in Description and Operation. 1. Install the outlet line over the frame. ^ Install the end with violet tape between the frame and the body. 2. Connect the outlet line peanut fitting. 1 Connect the outlet lines. 2 Loosely install the nut. 3 Snap the peanut fitting into the torque retention bracket. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8028 3. Install the outlet line. ^ Starting from the rear of the vehicle install the end with the violet tape over the frame crossmember and between the main member and the muffler heat shield. 4. Connect the outlet line peanut fitting to the outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. 1 Connect the outlet lines. 2 Loosely install the nut. 5. Install the outlet line. ^ Starting from the rear of the vehicle, install the end with the yellow tape between the frame and the muffler heat shield. 6. Connect the outlet line peanut fitting to the outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. ^ Connect the fitting and loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8029 7. Install the outlet line. 1 Remove the RH rear wheel and tire. 2 Install the end with the orange tape between the frame and the body through the rear wheel opening. 8. Connect the outlet line peanut fitting to the outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. ^ Connect the fitting and loosely install the nut. 9. Install the outlet line. ^ Install the end of the tube with no tape through the floor. 10. Connect the outlet line peanut fitting to outlet line. Refer to illustration: Multiple-Piece Auxiliary A/C Heater Line Kit. ^ Connect the fitting and loosely install the nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8030 11. Tighten the five peanut fittings. 12. Install the line brackets. 1 Position the bracket. 2 Install the nut. 3 Snap the line securely into the bracket. CAUTION: Overtightening of the nut will cause the stud to break away from the floor pan. NOTE: The bracket must be positioned equally between the white location marks on the line. 13. Install the muffler heat shield. 1 Position the shield 2 Install the nuts. 14. Lower the vehicle. 15. Turn the air suspension switch on, if equipped. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8031 16. Connect the outlet line to the auxiliary evaporator case line. 17. Install the grommet seal and retainer. NOTE: Maker sure that the lines are entering through the center of the floor opening and that the retainer locating marks are positioned correctly. 18. Install the quarter trim access panel. 19. Evacuate and charge the A/C system. Refer to: Heating and Air Conditioning, Service and Repair, Evacuation and Charging Procedure, See: Service and Repair/Evacuation and Charging Procedure 20. Install the spare tire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8032 Hose/Line HVAC: Service and Repair Main Climate Control REMOVAL 1. Perform the Refrigerant Discharging and Recovery Procedure. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Discharging and Recovery Procedure, See: Service and Repair/Refrigerant Discharging and Recovery procedure 2. Disconnect the condenser to evaporator line spring lock coupling from the A/C evaporator core. 3. Disconnect the A/C condenser core lower line. 1 Remove the nut. 2 Disconnect the A/C condenser core lower line. 4. Remove the tube bracket nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Auxiliary Climate Control > Page 8033 5. Remove the suction accumulator/drier bracket clamp bolt. 6. Remove the evaporator to condenser tube. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seal with PAG Compressor Oil, YN-12c, F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. 2. Evacuate and charge the A/C system. Refer to: Heating and Air Conditioning, Service and Repair, Evacuation and Charging Procedure, See: Service and Repair/Evacuation and Charging Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Page 8034 Spring Lock Coupling Disconnect Tool Set Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair Housing Assembly HVAC: Service and Repair REMOVAL NOTE: ^ Replacement of the suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. ^ If an A/C evaporator core leak is suspected, the A/C evaporator core must be leak tested before it is removed from the vehicle. 1. Perform the Refrigerant Discharging and Recovery Procedure. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Discharging and Recovery Procedure, See: Service and Repair/Refrigerant Discharging and Recovery procedure 2. Drain the radiator. 3. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Installation 4. Remove the junction block splash shield. 5. Disconnect the cable ends. 6. Remove the junction block bracket. 1 Disengage the connector. 2 Remove the screws. 3 Remove the junction block bracket. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 8038 7. Disconnect the heater core hose couplings. 8. Disconnect the refrigerant line spring lock couplings from the A/C evaporator core. 9. Remove the RH A/C plenum demister adapter. 1 Remove the screw. 2 Remove the RH A/C plenum demister adapter. 10. Remove the heater core outlet bracket. 1 Remove the screws. 2 Remove the bracket. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 8039 11. Remove the plenum assembly top. 1 Remove the 14 screws. 2 Remove the plenum assembly top. 12. Remove the A/C evaporator core from the plenum assembly. INSTALLATION 1. To install, reverse the removal procedure. ^ Service the new A/C evaporator core with the correct amount of PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C), or equivalent, meeting Ford specification WSH-M1C231-B. 2. Perform Evacuation and Charging Procedure. Refer to: Heating and Air Conditioning, Service and Repair, Evacuation and Charging Procedure, See: Service and Repair/Evacuation and Charging Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8044 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8045 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8046 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 8047 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Capacity without auxiliary Capacity with auxiliary R-134a Refrigerant YN-19 37 oz (US) 62 oz (US) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 8050 Refrigerant: Fluid Type Specifications R-134a Refrigerant Ford Part Number................................................................................................................................. ...................................................Motorcraft YN-19 Ford Specification................................................................................................................................. ....................................................WSH-M17B19-A Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 8051 Refrigerant: Service Precautions The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun. Ozone Depletion Scientific research performed over the past 15 years links the release of chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere where they react with and destroy ozone molecules. Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher incidents of cancer as well as global warming. When viewed from a global perspective, ozone depletion holds an enormous potential for damage. Upper Level Vs. Ground Level Ozone Confusion often arises when we hear about the necessity of the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial but the same compound, when located at ground level, is harmful to humans, animals, crops and vegetation. Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with nitrogen oxides (NOx) in the presence of sunlight and heat. Montreal Protocol In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this agreement leading to an end of production of R12 in December, 1995, in all developed countries. As established by the Montreal Protocol, R12 production in developed countries has ceased. Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning systems. Additional Information Sources For more complete and detailed explanations of the above policies, please refer to: http://www.epa.gov/ozone/ Technician Certification Organizations providing technician refrigerant recovery and recycling certification include: National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2 Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/ International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX 76147-2000 Phone: (817) 732-4600 Fax: (817) 732-9610 http://www.imaca.org/ Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041 Phone: 215-679-2220 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 8052 Fax: 215-541-4635 http://www.macsw.org/ Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 8053 Refrigerant: Service and Repair SPECIAL SERVICE TOOL(S) CAUTION: The A/C refrigerant of all vehicles must be identified and analyzed prior to refrigerant charging. Failure to do so can contaminate the shop bulk refrigerant and other vehicles. See: Service and Repair/Identifying Refrigerants 1. Connect the R-134a A/C Refrigerant Center to the low and high-pressure service gauge port valves. 2. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer. 3. Once the service center has recovered the vehicle A/C system refrigerant, close the service center inlet valve (if so equipped). Then switch off the power supply. 4. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system vacuum level as shown on the gauge. If the pressure does not rise, disconnect the recovery station hose(s). 5. If the system pressure rises, repeat steps 2 through 5 until the vacuum level remains stable for two minutes. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Fluid Type Specifications Refrigerant Oil: Fluid Type Specifications PAG Refrigerant Compressor Oil (R-134a Systems) Ford Part Number................................................................................................................................. ................F7AZ-19589-DA (Motorcraft YN-12-C) Ford Specification................................................................................................................................. ...................................................WSH-M1C231-B Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 8058 Refrigerant Oil: Service and Repair CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed, some of the refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. 1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. ^ If the amount of oil drained from the old A/C compressor is between 85 - 142 ml (3 - 5 ounces), pour the same amount plus 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. ^ If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 ounces), pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. ^ If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces), pour 85 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor. NOTE: Service A/C compressors are shipped without compressor oil. 2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier cylinder and drain the oil into a calibrated container. 1 Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B. 3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 8059 4. For the A/C condenser core, add 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet tube. 5. Add 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B to the suction accumulator/drier inlet tube when performing each of the following repairs: ^ replacement of the A/C evaporator core orifice ^ replacement of the A/C compressor pressure relief valve ^ replacement of a refrigerant line ^ repair of an O-ring seal leak ^ repair of a charge port leak 6. Installation of new components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications Refrigerant Pressure Sensor / Switch: Mechanical Specifications Pressure Cut Off Switch 6.8 - 13.6 Nm Junction block bracket screw 12 Nm Starter relay cable nut 8 Nm Starter relay cable ends 8 Nm A/C Cycling Switch 324 kPa Close Maximum A/C Cycling Switch 152 kPa Open Minimum Pressure Cut Off Switch 6.8 - 13.6 Nm Junction block bracket screw 12 Nm Starter relay cable nut 8 Nm Starter relay cable ends 8 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 8064 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications A/C Cycling Switch 324 kPa Close Maximum A/C Cycling Switch 152 kPa Open Minimum A/C Compressor Pressure Relief Valve 3103 kPa Opens At Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch Refrigerant Pressure Sensor / Switch: Locations Compressor Cut-Off/Cycling Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8067 Manual A/C Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8068 Electronic Automatic Temperature Control Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8069 Refrigerant System Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8070 Component Views Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8071 Component Views Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8072 Refrigerant Pressure Sensor / Switch: Locations A/C Pressure Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8073 Manual A/C Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8074 Electronic Automatic Temperature Control Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8075 Refrigerant System Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8076 Component Views Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8077 Component Views Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Sensor Air Conditioning Pressure Sensor Typical Air Conditioning Pressure Sensor A/C Pressure Sensor Output Voltage VS Pressure Chart The Air Conditioning Pressure (A/C pressure) sensor is located in the high pressure (discharge) side of the air conditioning A/C system. The A/C pressure sensor provides a voltage signal to the Powertrain Control Module (PCM) that is proportional to the A/C pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor > Page 8080 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator. ^ A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. ^ This allows the suction pressure inside the suction accumulator to control the operation of the A/C cycling switch. ^ The electrical switch contacts open when the suction pressure drops to 152 - 193 kPa (22 - 28 psi). ^ The contacts close when the suction pressure rises to 276 - 324 kPa (40 - 47 psi). ^ When the A/C cycling switch contacts close, the A/C clutch field coil is energized. ^ When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. ^ The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. ^ This prevents icing of the A/C evaporator core and blockage of airflow. ^ It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Wide Open Throttle A/C Cut-Off Wide Open Throttle A/C Cut-Off Mustang The Wide Open Throttle Air Conditioning Cut-off (WAC) output is used by the PCM to disengage the A/C clutch when A/C compressor operation is not desirable. Under normal conditions, with the A/C off, the PCM will ground the WAC output, which opens the normally closed WOT A/C cut-off relay inside the constant control relay module. When the A/C demand switch is turned on, and the A/C cycling switch and A/C high pressure switch high pressure contacts are closed, voltage is supplied to the WOT A/C cut-off relay contacts and to the ACCS circuit. The voltage on the ACCS circuit indicates to the PCM that A/C is requested. The PCM will then verify that A/C clutch operation is desirable (for example, engine not cranking, overheated or not at WOT). If A/C clutch operation is desirable, the PCM will adjust idle speed as necessary and "unground" the WAC output. This closes the normally closed WOT A/C cut-off relay and allows voltage to be supplied to the A/C clutch. All Others For these applications, the wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), ACCS). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the WAC output, closing the relay contacts and sending voltage to the A/C clutch. Air Conditioning Cycling Switch PCM Inputs Air Conditioning Cycling Switch The Air Conditioning (A/C) cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C cycling switch opens, the PCM will turn off the A/C clutch. For information on the specific function of the A/C cycling switch, refer to Climate Control system. The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are closed, voltage is supplied to the ACCS circuit at the PCM. Refer to the applicable Wiring Diagram 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. For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. NOTE: The Town Car, Continental, LS6/LS8 and Windstar 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 BUS + and BUS - (SCP) communication. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor > Page 8081 Air Conditioning High Pressure Switch Typical Air Conditioning Pressure Sensor Air Conditioning 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 two-speed 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 will result 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 will then turn on the high speed fan to help reduce the pressure. The A/C pressure cutoff switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. ^ The A/C pressure cutoff switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. ^ A valve depressor, located inside the threaded end of the A/C pressure cutoff switch, presses on the Schrader valve stem. ^ This allows the A/C pressure cutoff switch to monitor the compressor discharge pressure. ^ When the compressor discharge pressure rises to approximately 2,896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. ^ When the pressure drops to approximately 1724 kPa (250 psi) the contacts close to allow operation of the A/C compressor. ^ It is not necessary to discharge the refrigerant system to remove the A/C pressure cutoff switch. For additional information, refer to the Wiring Diagrams. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Compressor Cut-Off/Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair Compressor Cut-Off/Cycling Switch REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the junction block splash shield. 3. Disconnect the cable ends. 4. Remove the junction block bracket. 1 Disengage the connector. 2 Remove the screws. 3 Remove the junction block bracket. 5. Disconnect the A/C cycling pressure switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Compressor Cut-Off/Cycling Switch > Page 8084 6. Remove the A/C cycling switch from the top of the suction accumulator. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seal with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C), or equivalent, meeting Ford specification WSH-M1C231-B. 2. Carry out the refrigerant system Leak Detection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Compressor Cut-Off/Cycling Switch > Page 8085 Refrigerant Pressure Sensor / Switch: Service and Repair Pressure Cutoff Switch REMOVAL 1. Disconnect the electrical connector. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. To install, reverse the removal procedure. 1 Lubricate the O-ring seal with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C), or equivalent, meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay Blower Motor Relay: Locations Blower Motor Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 8091 Located in the Blower/Flasher Relay Block, which is located behind the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Blower Motor Relay > Page 8092 Blower Motor Relay: Locations Console Blower Relay Located in the RPO Relay Block #1, which is located in the dash, above the passenger air bag. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay Blower Motor Relay: Testing and Inspection Blower Motor Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Blower Motor Relay > Page 8095 Blower Motor Relay: Testing and Inspection Console Blower Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8099 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8100 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 8101 Compressor Clutch Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module Control Module HVAC: Locations Electronic Climate Control Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 8106 Component Views Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 8107 Component Views Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Electronic Climate Control Module > Page 8108 Electronic Automatic Temperature Control Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module Control Module HVAC: Diagrams Electronic Climate Control Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module > Page 8111 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Electronic Climate Control Module > Page 8112 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Page 8113 Control Module HVAC: Description and Operation The A/C blower motor speed control is a Pulse Width Modulated (PWM) type which provides variable blower speed control of the blower motor. The A/C blower motor speed control is controlled by switching the control signal voltage of 5 volts OFF and ON 2,000 times per second. By varying the ratio of time on (+5 volts) to time off (0 volts), the EATC module tells the A/C blower motor speed control how fast the blower motor should run. The A/C blower motor speed control has the following features: ^ Has circuitry to protect the blower motor from burning out in the event of a locked rotor condition. ^ Can compensate for changes in battery positive voltage (B+) which prevents the blower speed from slowing down when the engine is idling and will provide up to a maximum of 30 amperes for blower motor operation with battery voltages between 10 and 16 volts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Page 8114 Control Module HVAC: Service and Repair REMOVAL 1. Disengage the stops and lower the glove compartment door. 2. Remove the kickpad. 3. Disengage the aspirator hose from the bracket. NOTE: Part shown out of vehicle position. 4. Disengage the blower motor speed control mounting bracket from the instrument panel. 5. Disconnect the connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Page 8115 6. Disengage the retaining tabs and remove the blower motor speed control from the mounting bracket. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations System Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations > Page 8119 Located in the RPO Relay Block #2, which is located at the front of the left rear wheelwell. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Service and Repair Air Conditioning Switch: Service and Repair REMOVAL 1. Remove the control assembly. For additional information, refer to Control Assembly-Manual A/C. 2. Remove the function selector. 1 Depress the snap tabs. 2 Remove the function selector. NOTE: The knob will drop off as the function selector is removed. 3. Remove the temperature blend control switch. 1 Remove the screw. 2 Rotate and pull the temperature blend control switch. NOTE: The knob will drop off as the temperature blend control switch is removed. 4. Remove the blower motor switch. 1 Depress the snap tabs. 2 Remove the blower motor switch. NOTE: The knob will drop off as the blower motor switch is removed. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications Ambient Temperature Sensor / Switch HVAC: Specifications Ambient Air Sensor Bracket Bolt 9 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 8127 Ambient Temperature Sensor / Switch HVAC: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 8128 Electronic Automatic Temperature Control Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 8129 Ambient Temperature Sensor / Switch HVAC: Description and Operation The A/C ambient air temperature sensor and bracket: ^ is located in front of the A/C condenser core near the center of the vehicle. ^ contains a thermistor which measures the temperature of outside air as a resistance and sends that reading to the EATC module. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Specifications > Page 8130 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Remove the pin-type retainers and remove the radiator sight shield. 2. Disconnect the connector. 3. Remove the bolt and remove the ambient air temperature sensor panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Front Blower Motor Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Front Blower Motor Switch > Page 8135 Blower Motor Switch: Diagrams Rear Blower Motor Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations Cabin Temperature Sensor / Switch: Locations Component Views Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 8139 Component Views Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 8140 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 8141 Cabin Temperature Sensor / Switch: Description and Operation The in-car temperature sensor operates in the following manner: ^ A thermistor in the in-car temperature sensor measures air temperature inside the passenger compartment. ^ An automatic temperature control sensor hose and elbow is connected between the plenum assembly and the in-car temperature sensor. ^ The automatic temperature control sensor hose and elbow uses air from the plenum assembly air stream to create a suction at the in-car temperature sensor. ^ The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 8142 Cabin Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the center instrument panel finish panel. 1 Carefully pry to release the four clips. 2. If equipped, disconnect the 4WD control switch connector. 3. Remove the steering column cover panel. 4. Remove the headlamp switch. For additional information, refer to Lighting and Horns. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 8143 5. Remove the LH instrument panel finish panel. 1 Remove the screws. 2 Remove the LH instrument panel finish panel. 6. Remove the center instrument panel finish panel. 1 Remove the screws. 2 Remove the center instrument panel finish panel. 7. Remove the screw. 8. Disconnect the electrical connector and remove the sensor from the hose. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications Refrigerant Pressure Sensor / Switch: Mechanical Specifications Pressure Cut Off Switch 6.8 - 13.6 Nm Junction block bracket screw 12 Nm Starter relay cable nut 8 Nm Starter relay cable ends 8 Nm A/C Cycling Switch 324 kPa Close Maximum A/C Cycling Switch 152 kPa Open Minimum Pressure Cut Off Switch 6.8 - 13.6 Nm Junction block bracket screw 12 Nm Starter relay cable nut 8 Nm Starter relay cable ends 8 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 8148 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications A/C Cycling Switch 324 kPa Close Maximum A/C Cycling Switch 152 kPa Open Minimum A/C Compressor Pressure Relief Valve 3103 kPa Opens At Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch Refrigerant Pressure Sensor / Switch: Locations Compressor Cut-Off/Cycling Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8151 Manual A/C Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8152 Electronic Automatic Temperature Control Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8153 Refrigerant System Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8154 Component Views Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8155 Component Views Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8156 Refrigerant Pressure Sensor / Switch: Locations A/C Pressure Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8157 Manual A/C Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8158 Electronic Automatic Temperature Control Electrical Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8159 Refrigerant System Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8160 Component Views Part 1 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Compressor Cut-Off/Cycling Switch > Page 8161 Component Views Part 2 Of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Sensor Air Conditioning Pressure Sensor Typical Air Conditioning Pressure Sensor A/C Pressure Sensor Output Voltage VS Pressure Chart The Air Conditioning Pressure (A/C pressure) sensor is located in the high pressure (discharge) side of the air conditioning A/C system. The A/C pressure sensor provides a voltage signal to the Powertrain Control Module (PCM) that is proportional to the A/C pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor > Page 8164 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator. ^ A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. ^ This allows the suction pressure inside the suction accumulator to control the operation of the A/C cycling switch. ^ The electrical switch contacts open when the suction pressure drops to 152 - 193 kPa (22 - 28 psi). ^ The contacts close when the suction pressure rises to 276 - 324 kPa (40 - 47 psi). ^ When the A/C cycling switch contacts close, the A/C clutch field coil is energized. ^ When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. ^ The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. ^ This prevents icing of the A/C evaporator core and blockage of airflow. ^ It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Wide Open Throttle A/C Cut-Off Wide Open Throttle A/C Cut-Off Mustang The Wide Open Throttle Air Conditioning Cut-off (WAC) output is used by the PCM to disengage the A/C clutch when A/C compressor operation is not desirable. Under normal conditions, with the A/C off, the PCM will ground the WAC output, which opens the normally closed WOT A/C cut-off relay inside the constant control relay module. When the A/C demand switch is turned on, and the A/C cycling switch and A/C high pressure switch high pressure contacts are closed, voltage is supplied to the WOT A/C cut-off relay contacts and to the ACCS circuit. The voltage on the ACCS circuit indicates to the PCM that A/C is requested. The PCM will then verify that A/C clutch operation is desirable (for example, engine not cranking, overheated or not at WOT). If A/C clutch operation is desirable, the PCM will adjust idle speed as necessary and "unground" the WAC output. This closes the normally closed WOT A/C cut-off relay and allows voltage to be supplied to the A/C clutch. All Others For these applications, the wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is normally open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), ACCS). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the WAC output, closing the relay contacts and sending voltage to the A/C clutch. Air Conditioning Cycling Switch PCM Inputs Air Conditioning Cycling Switch The Air Conditioning (A/C) cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C cycling switch opens, the PCM will turn off the A/C clutch. For information on the specific function of the A/C cycling switch, refer to Climate Control system. The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are closed, voltage is supplied to the ACCS circuit at the PCM. Refer to the applicable Wiring Diagram 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. For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. NOTE: The Town Car, Continental, LS6/LS8 and Windstar 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 BUS + and BUS - (SCP) communication. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Sensor > Page 8165 Air Conditioning High Pressure Switch Typical Air Conditioning Pressure Sensor Air Conditioning 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 two-speed 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 will result 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 will then turn on the high speed fan to help reduce the pressure. The A/C pressure cutoff switch is used to interrupt A/C compressor operation in the event of high system discharge pressures. ^ The A/C pressure cutoff switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. ^ A valve depressor, located inside the threaded end of the A/C pressure cutoff switch, presses on the Schrader valve stem. ^ This allows the A/C pressure cutoff switch to monitor the compressor discharge pressure. ^ When the compressor discharge pressure rises to approximately 2,896 kPa (420 psi), the switch contacts open, disengaging the A/C compressor. ^ When the pressure drops to approximately 1724 kPa (250 psi) the contacts close to allow operation of the A/C compressor. ^ It is not necessary to discharge the refrigerant system to remove the A/C pressure cutoff switch. For additional information, refer to the Wiring Diagrams. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Compressor Cut-Off/Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair Compressor Cut-Off/Cycling Switch REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the junction block splash shield. 3. Disconnect the cable ends. 4. Remove the junction block bracket. 1 Disengage the connector. 2 Remove the screws. 3 Remove the junction block bracket. 5. Disconnect the A/C cycling pressure switch electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Compressor Cut-Off/Cycling Switch > Page 8168 6. Remove the A/C cycling switch from the top of the suction accumulator. INSTALLATION 1. To install, reverse the removal procedure. ^ Lubricate the O-ring seal with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C), or equivalent, meeting Ford specification WSH-M1C231-B. 2. Carry out the refrigerant system Leak Detection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Compressor Cut-Off/Cycling Switch > Page 8169 Refrigerant Pressure Sensor / Switch: Service and Repair Pressure Cutoff Switch REMOVAL 1. Disconnect the electrical connector. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. To install, reverse the removal procedure. 1 Lubricate the O-ring seal with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C), or equivalent, meeting Ford specification WSH-M1C231-B. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 8173 Solar Sensor: Description and Operation The A/C sunload sensor: ^ is located on the top side of the instrument panel. ^ contains a photovoltaic diode that is sensitive to light. ^ has some unspecified resistance across the terminals depending upon the amount of light reaching the photovoltaic diode; therefore the only test that can be performed is for an internal short circuit. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 8174 Solar Sensor: Service and Repair REMOVAL 1. Remove the instrument panel upper finish panel. 2. Disconnect the connector. 3. Remove the A/C sunload sensor from the instrument panel upper finish panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations Clutch Cycling Orifice Tube Type Refrigerant System Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 8178 Refrigerant System Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 8179 Service Port HVAC: Description and Operation Service Gauge Port Valve The high-pressure service gauge port valve is located on the A/C manifold and tube. The low pressure service gauge port valve is located on the suction accumulator. The fitting is an integral part of the refrigeration line or component. ^ Special couplings are required for both the high side and low side service gauge ports. ^ A new Schrader-type valve core can be installed if the seal leaks. ^ Always install the A/C charging valve cap on the service gauge port valves after repairing the refrigerant system. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 8183 Solar Sensor: Description and Operation The A/C sunload sensor: ^ is located on the top side of the instrument panel. ^ contains a photovoltaic diode that is sensitive to light. ^ has some unspecified resistance across the terminals depending upon the amount of light reaching the photovoltaic diode; therefore the only test that can be performed is for an internal short circuit. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 8184 Solar Sensor: Service and Repair REMOVAL 1. Remove the instrument panel upper finish panel. 2. Disconnect the connector. 3. Remove the A/C sunload sensor from the instrument panel upper finish panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > System Relay, HVAC > Component Information > Locations System Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > System Relay, HVAC > Component Information > Locations > Page 8188 Located in the RPO Relay Block #2, which is located at the front of the left rear wheelwell. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Customer Safety Information Vacuum Harness HVAC: Customer Safety Information WARNING: BEFORE USING, OR HANDLING COMMERCIALLY AVAILABLE PAINT THINNER CONTAINING METHYL ETHYL KETONE (MEK), READ AND FOLLOW THE WARNING INFORMATION ON THE PRODUCT LABEL. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Customer Safety Information > Page 8193 Vacuum Harness HVAC: Technician Safety Information WARNING: BEFORE USING, OR HANDLING COMMERCIALLY AVAILABLE PAINT THINNER CONTAINING METHYL ETHYL KETONE (MEK), READ AND FOLLOW THE WARNING INFORMATION ON THE PRODUCT LABEL. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Page 8194 Vacuum Harness HVAC: Service and Repair Vacuum Tester Kit SPECIAL SERVICE TOOL(S) 1. Measure the length of the damaged area of the mini-tube vacuum hose. 2. Cut a piece of standard 3mm (0.125 inch) inner diameter vacuum hose approximately 25 mm (1 inch) longer than the damaged area of the mini-tube vacuum hose. 3. Cut off the mini-tube vacuum hose on each side of the damaged area. 4. Dip the mini-tube hose ends in commercially available paint thinner containing Methyl Ethyl Ketone (MEK). This solvent will seal the mini-tube in the vacuum hose. WARNING: READ THE WARNING INFORMATION ON THE PRODUCT LABEL. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (0.375 inch) into the ends of the standard 3 mm (0.125 inch) service vacuum hose section. 6. Shake the service joint after assembly to make sure the O-ring seal solvent is dispersed and the vacuum line is not plugged. 7. Test the system for a vacuum leak in the repair area. ^ Use the Vacuum Tester or equivalent. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service Precautions > Page 8195 Vacuum Tester Kit Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service and Repair Vacuum Reservoir HVAC: Service and Repair REMOVAL 1. Remove the battery and battery tray. For additional information, refer to Battery. 2. Disconnect the A/C vacuum tank hose from the A/C vacuum reservoir tank and bracket. 3. Remove the A/C vacuum reservoir tank and bracket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When positioning the A/C vacuum reservoir tank, make sure that the bottom locator and two top tabs align with the battery tray. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment Repairs and Inspections Required After a Collision: Service and Repair Inspection and Repair After A Supplemental Restraint System (SRS) Deployment Inspection and Repair After a Supplemental Restraint System (SRS) Deployment WARNING: Remove restraint system diagnostic tools from the vehicle prior to road testing. If tools are not removed, the supplemental restraint system (SRS) device may not deploy in a crash. Failure to follow this instruction may result in serious personal injury or death in a crash and possibly violate vehicle safety standards. NOTE: After diagnosing or repairing a supplemental restraint system (SRS), the restraint system diagnostic tools (if required) must be removed before operating the vehicle over the road. NOTE: Deployable devices (such as air bag modules, pretensioners) may deploy alone or in various combinations depending on the impact event. NOTE: Always refer to the appropriate workshop manual procedures prior to carrying out vehicle repairs affecting the SRS and safety belt system. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. NOTE: Refer to the correct removal and installation procedure for all SRS components being installed. When any deployable device or combination of devices are deployed and/or the restraints control module (RCM) has the DTC B1231 (Event Threshold Exceeded) in memory, the repair of the vehicle's SRS is to include the removal of all deployed devices and the installation of new deployable devices, the removal and installation of new impact sensors, and the removal and installation of a new RCM. DTCs must cleared from all required modules after repairs are carried out. Vehicles with occupant classification sensor (OCS) system 2. NOTE: After installation of new occupant classification sensor (OCS) system components carry out the OCS System Reset procedure as instructed in the workshop manual. Refer to the appropriate workshop manual for OCS system removal and installation procedure. When a vehicle has been involved in a collision and the occupant classification system module (OCSM) has DTC B1231 stored in memory, the repair of the OCS system is to include the following procedures for the specified system: - For rail type OCS system, inspect the passenger side floorpan for damage and repair as necessary. Install new OCS system rails. - For weight sensor bolt type OCS system, inspect the passenger side floorpan for damage and repair as necessary. Install a new seat track with OCS system weight sensor bolts. DTC must be cleared from the OCSM before carrying out Occupant Classification Sensor (OCS) System Reset. Do not install a new OCSM unless DTC B1231 cannot be cleared. - NOTE: Most bladder type OCSM do not store a DTC B1231 in memory after deployment. The DTC B1231 is stored only by the RCM. For bladder type OCS system, inspect for damage and repair as necessary. If installation of an OCS system component is required, an OCS system service kit must be installed. All vehicles 3. When any damage to the impact sensor mounting points or mounting hardware has occurred, repair or install new mounting points and mounting hardware as needed. 4. When the driver air bag module has deployed, a new clockspring must be installed. 5. New driver and/or front passenger safety belt systems (including retractors, buckles and height adjusters) must be installed if the vehicle is involved in a collision that results in deployment of the driver and/or front passenger safety belt pretensioners. For additional information, refer to Safety Belt System. 6. Inspect the entire vehicle for damage, including the following components: Steering column (deployable column if equipped) Instrument panel knee bolsters and mounting points Instrument panel braces and brackets Instrument panel and mounting points Seats and seat mounting points Safety belts, safety belt buckles and safety belt retractors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 8204 SRS wiring, wiring harnesses and connectors 7. After carrying out the review and inspection of the entire vehicle for damage, repair or install new components as needed. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 8205 Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After A Collision SAFETY BELT PROCEDURE AFTER A COLLISION WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support assemblies (slide bar), shoulder belt height adjusters, child safety seat tether attachments (if equipped), and attaching hardware should be inspected after any collision. New belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and replaced if either damage or incorrect operation is noted. NOTE: Safety belt assemblies should be periodically inspected to make sure they have not become damaged and that they remain in correct operating condition, particularly if they have been subjected to severe stress. Before installing the new safety belt assembly, the safety belt attaching areas must be inspected for damage and distortion. If the attaching points are damaged and distorted, the sheet metal must be reworked back to its original shape and structural integrity. Install the new safety belt(s) using the appropriate instructions. Perform the Functional Test. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Supplemental Restraint System ( SRS ) Depowering and Repowering Depowering Procedure Warning: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Warning: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F22 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. Warning: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 6. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 1. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse F22 (10A) to the CJB and close the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 4. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8211 The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Deactivation and Reactivation Supplemental Restraint System ( SRS ) Deactivation and Reactivation Special Tool(s) Deactivation Warning: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Warning: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. Warning: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Warning: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. Warning: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All Vehicles 1. Move and tilt the front seats to their highest and most forward position. 2. Turn all vehicle accessories OFF. 3. Turn the ignition switch to OFF. 4. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F22 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 5. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 6. Turn the ignition OFF. Warning: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8212 The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 7. Disconnect the battery ground cable (14301) and wait at least one minute. 8. Remove the two steering wheel back cover plugs. 9. Remove the two driver air bag module retaining bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8213 10. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Disconnect the horn switch electrical connector. 3. Remove the driver air bag module. 11. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8214 12. Remove the instrument panel relay cover. 13. Disconnect the passenger air bag module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8215 14. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicle without side airbags Caution: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. 15. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM) If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with side airbags 16. Disconnect the passenger seat side air bag electrical connector. 1. Slide and disengage the passenger seat side air bag electrical connector locking clip. 2. Push in to release the tab and disconnect the passenger seat side air bag electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8216 17. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 18. Disconnect the driver seat side air bag electrical connector. 1. Slide and disengage the driver seat side air bag electrical connector locking clip. 2. Push in to release the tab and disconnect the driver seat side air bag electrical connector. 19. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All Vehicles 20. Install the RCM fuse F22 (10A) to the CJB. 21. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8217 Reactivation All Vehicles 1. Remove the RCM fuse F22 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles with side airbags 3. Remove the restraint system diagnostic tool from the driver side seat air bag floor electrical connector. 4. Connect the driver seat side air bag electrical connector. 1. Connect the driver seat side air bag electrical connector. 2. Slide and engage the driver seat side air bag electrical connector locking clip. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8218 5. Remove the restraint system diagnostic tool from the passenger side seat air bag floor electrical connector. 6. Connect the passenger side seat air bag electrical connector. 1. Connect the passenger side seat air bag electrical connector. 2. Slide and engage the passenger side seat air bag electrical connector locking clip. All Vehicles 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8219 8. Connect the passenger air bag module electrical connector. 9. Install the instrument panel relay cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8220 10. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Connect and position the driver air bag module. 1. Connect the horn switch electrical connector. 2. Connect the driver air bag module electrical connector. 3. Position the driver air bag module to the steering wheel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8221 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 14. 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. 15. Turn the ignition switch from OFF to ON. 16. Install the RCM fuse F22 (10A) to the CJB and close the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 17. Connect the battery ground cable. 18. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8222 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Is the air bag system connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Are the side air bag electrical connectors beneath the front seats connected? 4. Is the Restraints Control Module (RCM) connected? 5. Is the vehicle battery connected? Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Specifications Air Bag: Specifications Driver Air Bag Module 11 Nm Passenger Air Bag Module 9 Nm Side Air Bag Module 9 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Air Bag Module Air Bag: Description and Operation Driver Air Bag Module Driver Air Bag Module The driver air bag module: ^ is installed as an assembly. ^ is mounted in the center of the steering wheel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Air Bag Module > Page 8228 Air Bag: Description and Operation Driver Side Air Bag Module NOTE: References to side air bag modules refer to the seat-mounted and not to the steering wheel or instrument panel-mounted air bag components of the Supplemental Restraint System (SRS). The driver side air bag module: ^ is installed as an assembly. ^ is mounted in the driver seat back. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Air Bag Module > Page 8229 Air Bag: Description and Operation Passenger Air Bag Module Passenger Air Bag Module The passenger air bag module: ^ is installed as an assembly. ^ is mounted in the RH side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Driver Air Bag Module > Page 8230 Air Bag: Description and Operation Passenger Side Air Bag Module NOTE: References to side air bag modules refer to the seat-mounted and not to the steering wheel or instrument panel-mounted air bag components of the Supplemental Restraint System (SRS). The passenger side air bag module: ^ is installed as an assembly. ^ is mounted in the passenger seat back. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation Air Bag: Service and Repair Removal and Installation Driver Air Bag Module REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL, DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the two back cover plugs from the steering wheel. 3. Remove the two driver air bag module retaining bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8233 4. Remove the driver air bag module. 1 Disconnect the driver air bag module electrical connector. 2 Disconnect the horn switch electrical connector. 3 Remove the driver air bag module. INSTALLATION 1. To install, reverse the removal procedure. WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ Make sure to tighten the retaining bolts to specification. 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8234 VEHICLE SAFETY STANDARDS. Passenger Air Bag Module REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE DEPLOYMENT DOOR FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED DEPLOYMENT DOORS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL, DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the instrument panel relay cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8235 3. Disconnect the passenger air bag module. 1 Disconnect the electrical connector. 2 Remove the upper retaining bolt. 4. Push in the two glove compartment door tabs and position downward. 5. Remove the two lower passenger air bag module retaining bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8236 6. Remove the passenger air bag module. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ Make sure to tighten the retaining bolts to specification. 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8237 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO MAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Side Air Bag Module REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ ANYTIME THE SIDE AIR BAG HAS DEPLOYED, THE SEAT BACKREST FRAME MUST BE REPLACED. DO NOT ATTEMPT TO REPAIR THE SEAT BACKREST FRAME OR SIDE AIR BAG MOUNTING BRACKET. THE SEAT BACKREST FRAME MUST BE INSTALLED NEW. FAILURE TO DO SO MAY CAUSE THE SIDE AIR BAG MODULE TO NOT FUNCTION CORRECTLY, POSSIBLY RESULTING IN PERSONAL INJURY. ^ INSPECT THE SIDE AIR BAG MODULE MOUNTING BRACKET FOR DAMAGE. IF THE MOUNTING BRACKET IS DAMAGED DO NOT ATTEMPT TO REPAIR THE SEAT BACKREST FRAME OR SIDE AIR BAG MODULE MOUNTING BRACKET. IF DAMAGED, THE SEAT BACKREST FRAME MUST BE INSTALLED NEW. FAILURE TO DO SO MAY CAUSE THE SIDE AIR BAG MODULE TO NOT FUNCTION CORRECTLY, POSSIBLY RESULTING IN PERSONAL INJURY. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING AN AIR BAG MODULE. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8238 ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ When replacing the side air bag after deploymentrefer to Side Air Bag / Service and Repair for additional information concerning the installation of a new side air bag. ^ 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. Disconnect the battery ground cable and wait at least one minute. 2. Remove the seat from the vehicle. 3. Separate the seat back trim cover side J-clips. 1 From under the trim cover, separate the hook and loop strip. 2 Separate the seat back trim cover side J-clips. WARNING: FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE AIR BAGS CANNOT BE REPAIRED, THEY ARE TO BE REPLACED (CLEANING IS PERMISSIBLE). 4. Separate the seat back trim cover lower J-clips. 5. Position the seat back trim cover back flap up. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8239 6. Separate the side air bag wire harness pin-type retainers from the seat back frame. ^ Pull any extra side air bag wire harness toward the side air bag to allow for removal. NOTE: If the pin-type retainers are damaged, install new retainers. This will keep the wire harness routed correctly. 7. Remove the side air bag plastic shield. 8. Remove the side air bag module retaining nuts. NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused, then reuse the side air bag module nuts. 9. Position the side air bag module and deployment chute away from the mounting bracket and seat back frame. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8240 10. Position the seat back trim cover and foam pad away from the seat back frame. 11. Remove the side air bag module from the deployment chute. 1 Invert the seat back trim cover. 2 Remove the side air bag module from the deployment chute. ^ Pull the side air bag module mounting studs back through the deployment chute openings and remove the side air bag module from the deployment chute. 12. Disconnect and remove the side air bag module. 1 Slide the side air bag electrical connector locking clip to disengage it. 2 Release the two connector tabs by pushing in on them and disconnect the side air bag module. 3 Remove the side air bag module. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT ^ ANYTIME THE SIDE AIR BAG HAS DEPLOYED, THE SEAT BACKREST FRAME MUST BE REPLACED. DO NOT ATTEMPT TO REPAIR THE SEAT BACKREST FRAME OR SIDE AIR BAG MOUNTING BRACKET. THE SEAT BACKREST FRAME MUST BE INSTALLED NEW. FAILURE TO DO SO MAY CAUSE THE SIDE AIR BAG MODULE TO NOT FUNCTION CORRECTLY, POSSIBLY RESULTING IN PERSONAL INJURY. ^ INSPECT THE SIDE AIR BAG MODULE MOUNTING BRACKET FOR DAMAGE. IF THE MOUNTING BRACKET IS DAMAGED DO NOT ATTEMPT TO REPAIR THE SEAT BACKREST FRAME OR SIDE AIR BAG MODULE MOUNTING BRACKET. IF DAMAGED, THE SEAT BACKREST FRAME MUST BE INSTALLED NEW. FAILURE TO DO SO MAY CAUSE THE SIDE AIR BAG MODULE TO NOT FUNCTION CORRECTLY, POSSIBLY RESULTING IN PERSONAL INJURY. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8241 ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: 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. Connect the side air bag module electrical connector. 1 Install the connector to the side air bag module. 2 Slide the side air bag module electrical connector locking clip to secure the connector to the side air bag module. 2. Make sure the electrical connector is securely fastened to the side air bag module. 3. Position the side air bag module into the deployment chute with the alignment pin offset to the top and the electrical connector to the bottom of the seat back. This will position the alignment pin correctly when the side air bag module and deployment chute are mounted to the seat back frame mounting bracket. WARNING: ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE INTO THE DEPLOYMENT CHUTE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE FOR DAMAGE. THE DEPLOYMENT CHUTE MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE, THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. NOTE: The alignment pin will only allow the side air bag module to be installed to the seat back mounting bracket one way. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8242 4. Position the side air bag module in the deployment chute. 1 The side air bag module mounting studs must come through the deployment chute stud openings. 2 Wrap the remaining deployment chute flap around the side air bag module. 5. The side air bag module mounting studs must come through the deployment chute flap stud openings. 6. Install the side air bag module and deployment chute onto the front seat back frame mounting bracket. ^ The deployment chute should not have any wrinkles or folds where it contacts the seat back frame mounting bracket. ^ Tighten the retaining nuts to specification. WARNING: ^ INSPECT THE SIDE AIR BAG MODULE MOUNTING BRACKET FOR DAMAGE. IF THE MOUNTING BRACKET IS DAMAGED DO NOT ATTEMPT TO REPAIR THE SEAT BACKREST FRAME OR SIDE AIR BAG MODULE MOUNTING BRACKET. IF DAMAGED, THE SEAT BACKREST FRAME MUST BE INSTALLED NEW. FAILURE TO DO SO MAY CAUSE THE SIDE AIR BAG MODULE TO NOT FUNCTION CORRECTLY, POSSIBLY RESULTING IN PERSONAL INJURY. ^ INSPECT THE MOUNTING SURFACES OF THE DEPLOYMENT CHUTE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS, BEFORE INSTALLING THE SIDE AIR BAG MODULE DEPLOYMENT CHUTE ASSEMBLY. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULTING PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8243 7. Reposition the seat back pad and trim cover to the seat back frame. 8. Route the side air bag module wire harness and install the pin-type retainers. NOTE: If the side air bag module wire harness pin-type retainers have become damaged, new retainers must be installed to ensure correct wire routing. 9. Install the side air bag module plastic shield. ^ Check that the side air bag module plastic shield is correctly installed and secure. 10. Position the seat back trim cover back flap down. 11. Attach the seat back trim cover lower J-clips. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8244 12. Attach the seat back trim cover side J-clips. 1 Connect the seat back trim cover side J-clips. 2 Fold the hook and loop strip under the trim cover and attach it. 13. Install the seat into the vehicle. 14. Connect the battery ground cable. 15. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8245 Air Bag: Service and Repair Air Bag Disposal Procedures Deployed Air Bag 1. Dispose of the deployed air bag modules and safety belt pretensioners in the same manner as any other part to be scrapped. WARNING: ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. Undeployed Air Bag - Inoperative WARNING: CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER OR DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. NOTE: All inoperative air bag modules and safety belt pretensioners have been placed on the Mandatory Return List. All discolored or damaged air bag modules must be treated the same as any inoperative live air bag being returned. 1. Remove the inoperative component from the vehicle. 2. If installing a new driver air bag module: 1 For a new driver air bag module, record the necessary information and return the inoperative driver air bag module to Ford Motor Company. 2 For a new passenger air bag module, record the necessary information and return the inoperative driver air bag module to Ford Motor Company. NOTE: When installing a new air bag module, a prepaid return postcard is provided with the replacement air bag module. The serial number for the new part and the Vehicle Identification Number (VIN) must be recorded and sent to Ford Motor Company. Driver WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE OR SAFETY BELT RETRACTOR/PRETENSIONER ASSEMBLY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER OR DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ REMOTE DEPLOYMENT IS TO BE PERFORMED OUTDOORS WITH ALL PERSONNEL AT LEAST 6.1 METERS (20 FEET) AWAY TO ENSURE PERSONAL SAFETY. DUE TO THE LOUD REPORT WHICH OCCURS WHEN THE AIR BAG IS DEPLOYED, HEARING PROTECTION IS REQUIRED. ^ DO NOT PLACE THE DRIVER OR PASSENGER AIR BAG MODULE WITH THE TRIM COVER OR DEPLOYMENT DOOR FACING DOWN, AS THE FORCES OF THE DEPLOYING AIR BAG CAN CAUSE IT TO RICOCHET AND CAUSE PERSONAL INJURY. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8246 1. Remove the driver air bag from the vehicle. 2. Cut and strip the wires near the electrical connector. 3. Obtain two wires (20 gauge minimum) at least 6.1 meters (20 feet) long and attach one end of each wire to the stripped ends of the air bag module wires. 4. Place the air bag module on a flat surface in an open outdoor area with the trim cover facing upward. 5. Remain at least 6.1 meters (20 feet) away from the air bag module. 6. Deploy the air bag module by touching the other ends of the two wires to the terminals of a 12-volt battery. 7. To allow for cooling, wait at least ten minutes before approaching the deployed air bag. 8. Dispose of the deployed air bag module in the same manner as any other part to be scrapped. Passenger WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE OR SAFETY BELT RETRACTOR/PRETENSIONER ASSEMBLY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER OR DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ REMOTE DEPLOYMENT IS TO BE PERFORMED OUTDOORS WITH ALL PERSONNEL AT LEAST 6.1 METERS (20 FEET) AWAY TO ENSURE PERSONAL SAFETY. DUE TO THE LOUD REPORT WHICH OCCURS WHEN THE AIR BAG IS DEPLOYED, HEARING PROTECTION IS REQUIRED. ^ DO NOT PLACE THE DRIVER OR PASSENGER AIR BAG MODULE WITH THE TRIM COVER OR DEPLOYMENT DOOR FACING DOWN, AS THE FORCES OF THE DEPLOYING AIR BAG CAN CAUSE IT TO RICOCHET AND CAUSE PERSONAL INJURY. 1. Remove the passenger air bag from the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8247 2. Cut and strip the wires near the electrical connector. 3. Obtain two wires (20 gauge minimum) at least 6.1 meters (20 feet) long and attach one end of each wire to the stripped wires on the air bag module. 4. Place the air bag module on a flat surface in an open outdoor area with the deflector can facing downward. 5. Remain at least 6.1 meters (20 feet) away from the air bag module. 6. Deploy the air bag module by touching the other ends of the two wires to the terminals of a 12-volt battery. 7. To allow for cooling, wait at least ten minutes before approaching the deployed air bag. 8. Dispose of the deployed air bag module in the same manner as any other part to be scrapped. Side WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE OR SAFETY BELT RETRACTOR/PRETENSIONER ASSEMBLY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER OR DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ REMOTE DEPLOYMENT IS TO BE PERFORMED OUTDOORS WITH ALL PERSONNEL AT LEAST 6.1 METERS (20 FEET) AWAY TO ENSURE PERSONAL SAFETY. DUE TO THE LOUD REPORT WHICH OCCURS WHEN THE AIR BAG IS DEPLOYED, HEARING PROTECTION IS REQUIRED. ^ DO NOT PLACE THE SIDE AIR BAG MODULE WITH THE TEAR SEAM FACING DOWN OR THE ATTACHING STUDS FACING UPWARD, AS THE FORCES OF THE DEPLOYING AIR BAG CAN CAUSE IT TO RICOCHET AND CAUSE PERSONAL INJURY. 1. Remove the side air bag from the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8248 2. Obtain two wires (20 gauge minimum) at least 6.1 meters (20 feet) long and attach one end of each wire to the connector pins on the air bag module. 3. Place the air bag module on a flat surface in an open outdoor area with the tear seam facing upward and the attaching studs facing downward. 4. Remain at least 6.1 meters (20 feet) away from the air bag module. 5. Deploy the side air bag module by touching the other ends of the two wires to the terminals of a 12-volt battery. 6. To allow for cooling, wait at least ten minutes before approaching the deployed air bag. 7. Dispose of the deployed side air bag module in the same manner as any other part to be scrapped. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 8252 Air Bag Control Module: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 8253 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 8254 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) performs the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash. ^ monitors the air bag Supplemental Restraint System (SRS) for faults. ^ illuminates the air bag indicator if a fault is detected. ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). ^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safing sensor is internal to the RCM and is not repaired separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned OFF and then ON), the air bag indicator will remain lit for six seconds and then go out. If an SRS fault exists, the air bag indicator will then flash a two-digit Lamp Fault Code (LFC). The air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the Data Link Connector (DLC), using a scan tool. If the air bag indicator does not function, and a system fault is detected, the RCM will signal the GEM to activate the audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After the fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that an air bag deployment is required. The backup power supply will deplete its stored energy approximately 1 minute after the battery ground cable is disconnected. Sensor WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. The SRS uses four crash sensors. Two of the sensors are integral to the RCM and not separately serviceable. In addition, there are two side crash sensors mounted beneath their respective seats. The RCM is mounted to the center tunnel beneath the instrument panel. Mounting orientation is critical for correct operation of all crash sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation Air Bag Control Module: Service and Repair Removal and Installation REMOVAL AND INSTALLATION WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. NOTE: Before disconnecting the battery ground cable, move the front seats as far forward as possible. 2. Remove the trinket tray insert. 3. Remove the two screws. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 8257 4. Remove the console insert from the console and position it aside. 5. Remove the screws. 6. At the rear of the console, remove the screws (RH and LH side). 7. Lift the center console and position it as far to the rear as the electrical connections will allow. 8. Remove the instrument panel lower finish panel. NOTE: There are two pin-type fasteners on the LH side and one on the RH side. 9. Remove the RCM screw beneath the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 8258 10. Disconnect the RCM electrical connectors. 11. Remove the RCM. 1 Remove the screws. 2 Remove the RCM. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG RESTRAINT CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 12. To install, reverse the removal procedure. 13. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 8259 Air Bag Control Module: Service and Repair General Procedures "J" Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure. Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor Weld nuts must he installed in Weld Nut Repair - Missing Weld Nut, Restraints Control Module ( RCM) and Side Crash Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-5301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Missing Weld Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts as outlined in Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-5190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-5190). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 8260 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Stripped Weld Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190) 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Diagrams > Page 8264 Air Bag Sliding Contact: Description and Operation The air bag sliding contact: ^ is mounted on the steering column, behind the steering wheel. ^ allows uninterrupted electrical connection between the driver air bag module and the Restraints Control Module (RCM). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Diagrams > Page 8265 Air Bag Sliding Contact: Service and Repair REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT ^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE INSTALLED NEW, NOT REPAINTED. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL, DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the driver air bag module 3. Remove the steering wheel. NOTE: Make sure the wheels are in the straight-ahead position. 4. Apply two strips of masking tape across the air bag sliding contact to prevent accidental rotation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Diagrams > Page 8266 5. Twist the tilt wheel handle and shank and remove. 6. Remove the upper instrument panel steering column cover. 7. Remove the junction box fuse/relay panel cover. 8. Remove the lower instrument panel steering column cover. 1 Remove the two retaining bolts and disconnect the parking brake release lever. 2 Remove the two retaining bolts and disconnect the hood release lever. 3 Remove the six retaining bolts. 4 Remove the cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Diagrams > Page 8267 9. Remove the lower steering column shroud. 1 Remove the three retaining screws. 2 Remove the shroud. 10. Remove the ignition switch lock cylinder. 1 Position the lock cylinder to RUN. 2 Using a suitable tool, push upward on the cylinder release tab while pulling the cylinder outward. 11. Remove the upper steering column shroud. 12. Remove the Passive Anti-Theft System (PATS) transmitter. 1 Remove the retaining screw. 2 Remove the transmitter. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Diagrams > Page 8268 13. Remove the key-in-ignition warning indicator switch. 14. Disconnect the air bag sliding contact electrical connectors. 1 Separate the electrical connectors from the retaining bracket and disconnect from the harness. 2 Separate the air bag sliding contact wire harness from the clips retaining it to the steering column. 15. Remove the air bag sliding contact. 1 Pry the retaining clips loose. 2 Remove the air bag sliding contact. INSTALLATION 1. To install, reverse the removal procedure. WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Sliding Contact <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Diagrams > Page 8269 VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Side Crash Sensor Screws 12 Nm Restraint Control Module (RCM) Bracket Screws 12 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor Impact Sensor: Locations Driver Side Air Bag Crash Sensor Near driver seat. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 8275 Impact Sensor: Locations Passenger Side Air Bag Crash Sensor Near passenger seat. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 8276 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 8277 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 8278 Impact Sensor: Service and Repair REMOVAL AND INSTALLATION WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ Right side is shown, left side is similar. ^ The side crash sensors are located under the carpet beneath the front seats. 1. Disconnect the battery ground cable and wait at least one minute. 2. Position the side crash sensor out from under the seat. 1 Pull the carpet flap out from under the outboard side of the seat to expose the side crash sensor. 2 Remove the pin-type retainer. 3 Remove the bolts. 4 Position the side crash sensor out from under the seat. NOTE: A flap opening in the carpet, at the outboard side of the front seats already exists, for servicing the side crash sensor. 3. Remove the side crash sensor. 1 Disconnect the electrical connector. 2 Remove the side crash sensor and bracket. 4. To install, reverse the removal procedure. WARNING: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 8279 ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR CORRECT SYSTEM OPERATION. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 5. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Safing Sensor, Air Bag > Component Information > Description and Operation Safing Sensor: Description and Operation The safing sensor is internal to the Restraints Control Module (RCM) and is not repaired separately. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Specifications Side Air Bag: Specifications Side Air Bag Module 9 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation > Driver Side Air Bag Module Side Air Bag: Description and Operation Driver Side Air Bag Module NOTE: References to side air bag modules refer to the seat-mounted and not to the steering wheel or instrument panel-mounted air bag components of the Supplemental Restraint System (SRS). The driver side air bag module: ^ is installed as an assembly. ^ is mounted in the driver seat back. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description and Operation > Driver Side Air Bag Module > Page 8288 Side Air Bag: Description and Operation Passenger Side Air Bag Module NOTE: References to side air bag modules refer to the seat-mounted and not to the steering wheel or instrument panel-mounted air bag components of the Supplemental Restraint System (SRS). The passenger side air bag module: ^ is installed as an assembly. ^ is mounted in the passenger seat back. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Removal and Installation Side Air Bag: Service and Repair Removal and Installation REMOVAL WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ ANYTIME THE SIDE AIR BAG HAS DEPLOYED, THE SEAT BACKREST FRAME MUST BE REPLACED. DO NOT ATTEMPT TO REPAIR THE SEAT BACKREST FRAME OR SIDE AIR BAG MOUNTING BRACKET. THE SEAT BACKREST FRAME MUST BE INSTALLED NEW. FAILURE TO DO SO MAY CAUSE THE SIDE AIR BAG MODULE TO NOT FUNCTION CORRECTLY, POSSIBLY RESULTING IN PERSONAL INJURY. ^ INSPECT THE SIDE AIR BAG MODULE MOUNTING BRACKET FOR DAMAGE. IF THE MOUNTING BRACKET IS DAMAGED DO NOT ATTEMPT TO REPAIR THE SEAT BACKREST FRAME OR SIDE AIR BAG MODULE MOUNTING BRACKET. IF DAMAGED, THE SEAT BACKREST FRAME MUST BE INSTALLED NEW. FAILURE TO DO SO MAY CAUSE THE SIDE AIR BAG MODULE TO NOT FUNCTION CORRECTLY, POSSIBLY RESULTING IN PERSONAL INJURY. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING AN AIR BAG MODULE. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ When replacing the side air bag after deploymentrefer to Side Air Bag / Service and Repair for additional information concerning the installation of a new side air bag. ^ 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. Disconnect the battery ground cable and wait at least one minute. 2. Remove the seat from the vehicle. 3. Separate the seat back trim cover side J-clips. 1 From under the trim cover, separate the hook and loop strip. 2 Separate the seat back trim cover side J-clips. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8291 WARNING: FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE AIR BAGS CANNOT BE REPAIRED, THEY ARE TO BE REPLACED (CLEANING IS PERMISSIBLE). 4. Separate the seat back trim cover lower J-clips. 5. Position the seat back trim cover back flap up. 6. Separate the side air bag wire harness pin-type retainers from the seat back frame. ^ Pull any extra side air bag wire harness toward the side air bag to allow for removal. NOTE: If the pin-type retainers are damaged, install new retainers. This will keep the wire harness routed correctly. 7. Remove the side air bag plastic shield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8292 8. Remove the side air bag module retaining nuts. NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused, then reuse the side air bag module nuts. 9. Position the side air bag module and deployment chute away from the mounting bracket and seat back frame. 10. Position the seat back trim cover and foam pad away from the seat back frame. 11. Remove the side air bag module from the deployment chute. 1 Invert the seat back trim cover. 2 Remove the side air bag module from the deployment chute. ^ Pull the side air bag module mounting studs back through the deployment chute openings and remove the side air bag module from the deployment chute. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8293 12. Disconnect and remove the side air bag module. 1 Slide the side air bag electrical connector locking clip to disengage it. 2 Release the two connector tabs by pushing in on them and disconnect the side air bag module. 3 Remove the side air bag module. INSTALLATION WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT ^ ANYTIME THE SIDE AIR BAG HAS DEPLOYED, THE SEAT BACKREST FRAME MUST BE REPLACED. DO NOT ATTEMPT TO REPAIR THE SEAT BACKREST FRAME OR SIDE AIR BAG MOUNTING BRACKET. THE SEAT BACKREST FRAME MUST BE INSTALLED NEW. FAILURE TO DO SO MAY CAUSE THE SIDE AIR BAG MODULE TO NOT FUNCTION CORRECTLY, POSSIBLY RESULTING IN PERSONAL INJURY. ^ INSPECT THE SIDE AIR BAG MODULE MOUNTING BRACKET FOR DAMAGE. IF THE MOUNTING BRACKET IS DAMAGED DO NOT ATTEMPT TO REPAIR THE SEAT BACKREST FRAME OR SIDE AIR BAG MODULE MOUNTING BRACKET. IF DAMAGED, THE SEAT BACKREST FRAME MUST BE INSTALLED NEW. FAILURE TO DO SO MAY CAUSE THE SIDE AIR BAG MODULE TO NOT FUNCTION CORRECTLY, POSSIBLY RESULTING IN PERSONAL INJURY. ^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. NOTE: 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. Connect the side air bag module electrical connector. 1 Install the connector to the side air bag module. 2 Slide the side air bag module electrical connector locking clip to secure the connector to the side air bag module. 2. Make sure the electrical connector is securely fastened to the side air bag module. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8294 3. Position the side air bag module into the deployment chute with the alignment pin offset to the top and the electrical connector to the bottom of the seat back. This will position the alignment pin correctly when the side air bag module and deployment chute are mounted to the seat back frame mounting bracket. WARNING: ^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE FOR ANY FOREIGN OBJECTS BEFORE INSTALLING THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE FOUND REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ BEFORE INSTALLING THE SIDE AIR BAG MODULE INTO THE DEPLOYMENT CHUTE, CHECK IT FOR DAMAGE AND FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. ^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE FOR DAMAGE. THE DEPLOYMENT CHUTE MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE TO THE DEPLOYMENT CHUTE, THE SEAT BACK TRIM COVER AND DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. ^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. NOTE: The alignment pin will only allow the side air bag module to be installed to the seat back mounting bracket one way. 4. Position the side air bag module in the deployment chute. 1 The side air bag module mounting studs must come through the deployment chute stud openings. 2 Wrap the remaining deployment chute flap around the side air bag module. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8295 5. The side air bag module mounting studs must come through the deployment chute flap stud openings. 6. Install the side air bag module and deployment chute onto the front seat back frame mounting bracket. ^ The deployment chute should not have any wrinkles or folds where it contacts the seat back frame mounting bracket. ^ Tighten the retaining nuts to specification. WARNING: ^ INSPECT THE SIDE AIR BAG MODULE MOUNTING BRACKET FOR DAMAGE. IF THE MOUNTING BRACKET IS DAMAGED DO NOT ATTEMPT TO REPAIR THE SEAT BACKREST FRAME OR SIDE AIR BAG MODULE MOUNTING BRACKET. IF DAMAGED, THE SEAT BACKREST FRAME MUST BE INSTALLED NEW. FAILURE TO DO SO MAY CAUSE THE SIDE AIR BAG MODULE TO NOT FUNCTION CORRECTLY, POSSIBLY RESULTING IN PERSONAL INJURY. ^ INSPECT THE MOUNTING SURFACES OF THE DEPLOYMENT CHUTE AND THE SEAT BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS, BEFORE INSTALLING THE SIDE AIR BAG MODULE DEPLOYMENT CHUTE ASSEMBLY. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULTING PERSONAL INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT. 7. Reposition the seat back pad and trim cover to the seat back frame. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8296 8. Route the side air bag module wire harness and install the pin-type retainers. NOTE: If the side air bag module wire harness pin-type retainers have become damaged, new retainers must be installed to ensure correct wire routing. 9. Install the side air bag module plastic shield. ^ Check that the side air bag module plastic shield is correctly installed and secure. 10. Position the seat back trim cover back flap down. 11. Attach the seat back trim cover lower J-clips. 12. Attach the seat back trim cover side J-clips. 1 Connect the seat back trim cover side J-clips. 2 Fold the hook and loop strip under the trim cover and attach it. 13. Install the seat into the vehicle. 14. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8297 15. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8298 Side Air Bag: Service and Repair Air Bag Disposal Procedures Deployed Air Bag 1. Dispose of the deployed air bag modules and safety belt pretensioners in the same manner as any other part to be scrapped. WARNING: ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. Undeployed Air Bag - Inoperative WARNING: CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER OR DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. NOTE: All inoperative air bag modules and safety belt pretensioners have been placed on the Mandatory Return List. All discolored or damaged air bag modules must be treated the same as any inoperative live air bag being returned. 1. Remove the inoperative component from the vehicle. 2. If installing a new driver air bag module: 1 For a new driver air bag module, record the necessary information and return the inoperative driver air bag module to Ford Motor Company. 2 For a new passenger air bag module, record the necessary information and return the inoperative driver air bag module to Ford Motor Company. NOTE: When installing a new air bag module, a prepaid return postcard is provided with the replacement air bag module. The serial number for the new part and the Vehicle Identification Number (VIN) must be recorded and sent to Ford Motor Company. Undeployed Air Bag - Scrapped Vehicle Remote Deployment WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE OR SAFETY BELT RETRACTOR/PRETENSIONER ASSEMBLY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER OR DEPLOYMENT DOOR POINTED AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ REMOTE DEPLOYMENT IS TO BE PERFORMED OUTDOORS WITH ALL PERSONNEL AT LEAST 6.1 METERS (20 FEET) AWAY TO ENSURE PERSONAL SAFETY. DUE TO THE LOUD REPORT WHICH OCCURS WHEN THE AIR BAG IS DEPLOYED, HEARING PROTECTION IS REQUIRED. ^ DO NOT PLACE THE SIDE AIR BAG MODULE WITH THE TEAR SEAM FACING DOWN OR THE ATTACHING STUDS FACING UPWARD, AS THE FORCES OF THE DEPLOYING AIR BAG CAN CAUSE IT TO RICOCHET AND CAUSE PERSONAL INJURY. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Removal and Installation > Page 8299 1. Remove the side air bag from the vehicle. 2. Obtain two wires (20 gauge minimum) at least 6.1 meters (20 feet) long and attach one end of each wire to the connector pins on the air bag module. 3. Place the air bag module on a flat surface in an open outdoor area with the tear seam facing upward and the attaching studs facing downward. 4. Remain at least 6.1 meters (20 feet) away from the air bag module. 5. Deploy the side air bag module by touching the other ends of the two wires to the terminals of a 12-volt battery. 6. To allow for cooling, wait at least ten minutes before approaching the deployed air bag. 7. Dispose of the deployed side air bag module in the same manner as any other part to be scrapped. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Recalls for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions Technical Service Bulletin # 00L11 Date: 000201 Information O0L11 SPECIAL FIELD ACTION Certain 2000 and 2001 Model Year Expedition and Navigator and Certain 2001 Model Year F-150 Super Cab, Taurus, and Sable Vehicles - Revised Owner's Guide Child Tether Instruction Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Recalls for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8308 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Recalls for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8309 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $5,000 per vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Recalls for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8310 DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Owner's Guide Page Labels or Owner's Guides Owner's Guide page labels and new Owner's Guides for this program are being sent directly to customers of the affected vehicles. Additional labels (for customers who prefer to have this label installed at the dealership and arrive without the label) or Owner's Guides (for dealer stock units) may be ordered as follows: Call 1-800-325-5621 ^ Ask for an additional Owner's Guide page label or Owner's Guide for program OOL1 1 ^ Provide vehicle model year and make to obtain the correct Owner's Guide page label or Owner's Guide DEALER PRICE Dealers will not be charged for the Owner's Guide page labels or Owner's Guides ordered under this program. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 2001 MODEL YEAR TAURUS AND SABLE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Recalls for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8311 TAURUS OWNER'S GUIDE LABEL PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Recalls for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8312 SABLE OWNER'S GUIDE LABEL PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Recalls for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8313 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Recalls for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8314 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions Technical Service Bulletin # 00L11 Date: 000201 Information O0L11 SPECIAL FIELD ACTION Certain 2000 and 2001 Model Year Expedition and Navigator and Certain 2001 Model Year F-150 Super Cab, Taurus, and Sable Vehicles - Revised Owner's Guide Child Tether Instruction Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8320 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8321 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $5,000 per vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8322 DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Owner's Guide Page Labels or Owner's Guides Owner's Guide page labels and new Owner's Guides for this program are being sent directly to customers of the affected vehicles. Additional labels (for customers who prefer to have this label installed at the dealership and arrive without the label) or Owner's Guides (for dealer stock units) may be ordered as follows: Call 1-800-325-5621 ^ Ask for an additional Owner's Guide page label or Owner's Guide for program OOL1 1 ^ Provide vehicle model year and make to obtain the correct Owner's Guide page label or Owner's Guide DEALER PRICE Dealers will not be charged for the Owner's Guide page labels or Owner's Guides ordered under this program. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 2001 MODEL YEAR TAURUS AND SABLE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8323 TAURUS OWNER'S GUIDE LABEL PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8324 SABLE OWNER'S GUIDE LABEL PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8325 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8326 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 8331 Air Bag Control Module: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 8332 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 8333 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) performs the following functions: ^ signals the inflators to deploy the air bags in the event of a deployable crash. ^ monitors the air bag Supplemental Restraint System (SRS) for faults. ^ illuminates the air bag indicator if a fault is detected. ^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. ^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). ^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safing sensor is internal to the RCM and is not repaired separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned OFF and then ON), the air bag indicator will remain lit for six seconds and then go out. If an SRS fault exists, the air bag indicator will then flash a two-digit Lamp Fault Code (LFC). The air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the Data Link Connector (DLC), using a scan tool. If the air bag indicator does not function, and a system fault is detected, the RCM will signal the GEM to activate the audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After the fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that an air bag deployment is required. The backup power supply will deplete its stored energy approximately 1 minute after the battery ground cable is disconnected. Sensor WARNING: THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR CORRECT SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE CENTER TUNNEL AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION. The SRS uses four crash sensors. Two of the sensors are integral to the RCM and not separately serviceable. In addition, there are two side crash sensors mounted beneath their respective seats. The RCM is mounted to the center tunnel beneath the instrument panel. Mounting orientation is critical for correct operation of all crash sensors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation Air Bag Control Module: Service and Repair Removal and Installation REMOVAL AND INSTALLATION WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. NOTE: Before disconnecting the battery ground cable, move the front seats as far forward as possible. 2. Remove the trinket tray insert. 3. Remove the two screws. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 8336 4. Remove the console insert from the console and position it aside. 5. Remove the screws. 6. At the rear of the console, remove the screws (RH and LH side). 7. Lift the center console and position it as far to the rear as the electrical connections will allow. 8. Remove the instrument panel lower finish panel. NOTE: There are two pin-type fasteners on the LH side and one on the RH side. 9. Remove the RCM screw beneath the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 8337 10. Disconnect the RCM electrical connectors. 11. Remove the RCM. 1 Remove the screws. 2 Remove the RCM. WARNING: THE TIGHTENING TORQUE OF THE AIR BAG RESTRAINT CONTROL MODULE (RCM) RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 12. To install, reverse the removal procedure. 13. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 8338 Air Bag Control Module: Service and Repair General Procedures "J" Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedures and Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor before proceeding with the repair. ^ If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure. Weld Nut Repair-Missing Weld Nut, Restraints Control Module (RCM) and Side Crash Sensor Weld nuts must he installed in Weld Nut Repair - Missing Weld Nut, Restraints Control Module ( RCM) and Side Crash Sensor. ^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is in close proximity to the missing weld nut. 1. Obtain a "J" nut (part number N623332-5301) or any of the following optional "J" nuts (part numbers: N623342-S101, N800854-S100, N800925-S100). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet metal. 5. Tighten the attaching screws to specification. Missing Weld Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld nut(s). Read both this procedure and Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor before proceeding with the repair. ^ Use only this procedure if two or more weld nuts are missing, do not install the "J" nuts as outlined in Weld Nut Repair - "J" Nut, Restraints Control Module (RCM) and Side Crash Sensor. ^ Radiator support repair shown, others are similar. 1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-5190). 2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-5190). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Removal and Installation > Page 8339 3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole. 4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5. Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld nut in position. 8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut. 9. Metal finish as required. 10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws to specification. Stripped Weld Nut WARNING: ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). 1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190) 2. Drill out the internal threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation Seat Belt Warning Relay: Technical Service Bulletins Seat Belts - Warning System Operation Article No. 01-2-5 2/05/01 ^ TRIM - SEAT BELT WARNING SYSTEM - "BELT ^ MINDER" FUNCTION - OPERATION AND SERVICE ^ TIPS ^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND ^ SERVICE TIPS FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION, F-150, RANGER, WINDSTAR 2001 EXPLORER LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER ISSUE The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the instrument cluster. ACTION Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following Service Procedure. SERVICE PROCEDURE To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure. 1. Establish a session for the vehicle. 2. Select the "Toolbox" icon. 3. Select "Module Programming" and press the "Tick" mark. 4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark. 5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark. 6. WDS will display "Configuration Complete", then press the "Tick" mark. NOTE: IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE SAFETY BELT IS BUCKLED. NOTE: WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND FOR 4-8 SECONDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation > Page 8344 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 104000, 204000, 206000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Supplemental Restraint System ( SRS ) Depowering and Repowering Depowering Procedure Warning: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Warning: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F22 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. Warning: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 6. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 1. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse F22 (10A) to the CJB and close the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 4. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8350 The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Deactivation and Reactivation Supplemental Restraint System ( SRS ) Deactivation and Reactivation Special Tool(s) Deactivation Warning: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Warning: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. Warning: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Warning: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. Warning: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All Vehicles 1. Move and tilt the front seats to their highest and most forward position. 2. Turn all vehicle accessories OFF. 3. Turn the ignition switch to OFF. 4. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F22 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 5. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 6. Turn the ignition OFF. Warning: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8351 The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 7. Disconnect the battery ground cable (14301) and wait at least one minute. 8. Remove the two steering wheel back cover plugs. 9. Remove the two driver air bag module retaining bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8352 10. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Disconnect the horn switch electrical connector. 3. Remove the driver air bag module. 11. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8353 12. Remove the instrument panel relay cover. 13. Disconnect the passenger air bag module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8354 14. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicle without side airbags Caution: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. 15. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM) If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with side airbags 16. Disconnect the passenger seat side air bag electrical connector. 1. Slide and disengage the passenger seat side air bag electrical connector locking clip. 2. Push in to release the tab and disconnect the passenger seat side air bag electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8355 17. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 18. Disconnect the driver seat side air bag electrical connector. 1. Slide and disengage the driver seat side air bag electrical connector locking clip. 2. Push in to release the tab and disconnect the driver seat side air bag electrical connector. 19. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All Vehicles 20. Install the RCM fuse F22 (10A) to the CJB. 21. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8356 Reactivation All Vehicles 1. Remove the RCM fuse F22 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles with side airbags 3. Remove the restraint system diagnostic tool from the driver side seat air bag floor electrical connector. 4. Connect the driver seat side air bag electrical connector. 1. Connect the driver seat side air bag electrical connector. 2. Slide and engage the driver seat side air bag electrical connector locking clip. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8357 5. Remove the restraint system diagnostic tool from the passenger side seat air bag floor electrical connector. 6. Connect the passenger side seat air bag electrical connector. 1. Connect the passenger side seat air bag electrical connector. 2. Slide and engage the passenger side seat air bag electrical connector locking clip. All Vehicles 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8358 8. Connect the passenger air bag module electrical connector. 9. Install the instrument panel relay cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8359 10. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Connect and position the driver air bag module. 1. Connect the horn switch electrical connector. 2. Connect the driver air bag module electrical connector. 3. Position the driver air bag module to the steering wheel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8360 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 14. 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. 15. Turn the ignition switch from OFF to ON. 16. Install the RCM fuse F22 (10A) to the CJB and close the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 17. Connect the battery ground cable. 18. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 8361 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Is the air bag system connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Are the side air bag electrical connectors beneath the front seats connected? 4. Is the Restraints Control Module (RCM) connected? 5. Is the vehicle battery connected? Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > NHTSA00V396000 > Nov > 00 > Recall 00V396000: Child Restraint Anchor Non-Compliance Child Seat Tether Attachment: Recalls Recall 00V396000: Child Restraint Anchor Non-Compliance Certain sport utility vehicles, pickup trucks, and passenger vehicles fail to comply with the requirements of FMVSS 225, "Child Restraint Anchorage Systems." The affected Expedition/Navigator Owner Guides do not identify the locations of seating positions equipped with tether anchorages, and do not provide instructions for securing child seats to these tether anchorages. The F150 SC Owner Guides do not provide the procedure for securing child seats to the tether anchorages. The Taurus/Sable Owner Guides do not identify the center rear seating position as having latch compatible lower anchorages. In the event of a crash, the child seat may not be properly attached increasing the risk of injury to the child. Owners will be provided with owner guide inserts revised to provide the required information, and instructions for affixing these inserts to their Owner Guides. Customers will also be advised that if they prefer, their dealer will affix the inserts to their Owner Guides. Owner notification is expected to begin during January 2001. Owners who do not receive the free label and installation instructions within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions Technical Service Bulletin # 00L11 Date: 000201 Information O0L11 SPECIAL FIELD ACTION Certain 2000 and 2001 Model Year Expedition and Navigator and Certain 2001 Model Year F-150 Super Cab, Taurus, and Sable Vehicles - Revised Owner's Guide Child Tether Instruction Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8375 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8376 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $5,000 per vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8377 DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Owner's Guide Page Labels or Owner's Guides Owner's Guide page labels and new Owner's Guides for this program are being sent directly to customers of the affected vehicles. Additional labels (for customers who prefer to have this label installed at the dealership and arrive without the label) or Owner's Guides (for dealer stock units) may be ordered as follows: Call 1-800-325-5621 ^ Ask for an additional Owner's Guide page label or Owner's Guide for program OOL1 1 ^ Provide vehicle model year and make to obtain the correct Owner's Guide page label or Owner's Guide DEALER PRICE Dealers will not be charged for the Owner's Guide page labels or Owner's Guides ordered under this program. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 2001 MODEL YEAR TAURUS AND SABLE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8378 TAURUS OWNER'S GUIDE LABEL PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8379 SABLE OWNER'S GUIDE LABEL PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8380 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Recalls for Child Seat Tether Attachment: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8381 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > NHTSA00V396000 > Nov > 00 > Recall 00V396000: Child Restraint Anchor Non-Compliance Child Seat Tether Attachment: All Technical Service Bulletins Recall 00V396000: Child Restraint Anchor Non-Compliance Certain sport utility vehicles, pickup trucks, and passenger vehicles fail to comply with the requirements of FMVSS 225, "Child Restraint Anchorage Systems." The affected Expedition/Navigator Owner Guides do not identify the locations of seating positions equipped with tether anchorages, and do not provide instructions for securing child seats to these tether anchorages. The F150 SC Owner Guides do not provide the procedure for securing child seats to the tether anchorages. The Taurus/Sable Owner Guides do not identify the center rear seating position as having latch compatible lower anchorages. In the event of a crash, the child seat may not be properly attached increasing the risk of injury to the child. Owners will be provided with owner guide inserts revised to provide the required information, and instructions for affixing these inserts to their Owner Guides. Customers will also be advised that if they prefer, their dealer will affix the inserts to their Owner Guides. Owner notification is expected to begin during January 2001. Owners who do not receive the free label and installation instructions within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions Technical Service Bulletin # 00L11 Date: 000201 Information O0L11 SPECIAL FIELD ACTION Certain 2000 and 2001 Model Year Expedition and Navigator and Certain 2001 Model Year F-150 Super Cab, Taurus, and Sable Vehicles - Revised Owner's Guide Child Tether Instruction Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8391 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8392 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $5,000 per vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8393 DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Owner's Guide Page Labels or Owner's Guides Owner's Guide page labels and new Owner's Guides for this program are being sent directly to customers of the affected vehicles. Additional labels (for customers who prefer to have this label installed at the dealership and arrive without the label) or Owner's Guides (for dealer stock units) may be ordered as follows: Call 1-800-325-5621 ^ Ask for an additional Owner's Guide page label or Owner's Guide for program OOL1 1 ^ Provide vehicle model year and make to obtain the correct Owner's Guide page label or Owner's Guide DEALER PRICE Dealers will not be charged for the Owner's Guide page labels or Owner's Guides ordered under this program. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 2001 MODEL YEAR TAURUS AND SABLE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8394 TAURUS OWNER'S GUIDE LABEL PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8395 SABLE OWNER'S GUIDE LABEL PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8396 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat Tether Attachment: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 8397 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Page 8398 Child Seat Tether Attachment: Description and Operation Some manufacturers make child safety seats that include a tether strap that goes over the back of the vehicle seat and attaches to an anchoring point. Other manufacturers offer the tether strap as an accessory. Contact the manufacturer of the child safety seat for information about ordering a tether strap. Child safety seat tether anchors are manufactured into the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Specifications Safety Belt: Specifications Safety Belt Anchor Bolt 34-46 Nm Safety Belt Guide Bolt 34-46 Nm Safety Belt Guide Nut 34-46 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Service and Repair > Safety Belt Twisted At the Safety Belt Guide - Outboard Safety Belt: Service and Repair Safety Belt Twisted At the Safety Belt Guide - Outboard 1. Straighten the twisted belt webbing. 1 Grasp webbing at the safety belt guide. 2 Feed twisted portion of webbing up through safety belt guide. 2. Pull straightened belt downward to check for proper operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Service and Repair > Safety Belt Twisted At the Safety Belt Guide - Outboard > Page 8404 Safety Belt: Service and Repair Safety Belt Cleaning 1. Clean the safety belt webbing only with a mild soap solution recommended for cleaning upholstery or carpets. Follow the instructions provided with the soap. WARNING: DO NOT BLEACH OR RE-DYE THE WEBBING, AS THE WEBBING MAY WEAKEN. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Service and Repair > Safety Belt Twisted At the Safety Belt Guide - Outboard > Page 8405 Safety Belt: Service and Repair Replacement of the Weld Nut and Reinforcement 1. Remove the interior trim panel to expose the suspect anchor point. 2. Determine if the weld nut fully or the weld nut and reinforcement and weld nut are missing. If the B- or C- or D- pillar safety belt anchor nuts or reinforcements are stripped or missing, they should be replaced with a new nut or reinforcement. To install a missing weld nut only, proceed to Step 3. 3. Obtain a M12 weld nut, Part No. N806329, and a standard washer. 4. Drill out two 8 mm (5/16 in) diameter holes adjacent to the clearance hole. 5. Obtain a length of copper welding wire and feed through clearance hole in door frame opening until it becomes visible at the access hole. 6. Pull the wire through so that it may be secured to the weld nut and washer. 7. Pull the wire back up to the weld nut clearance hole. 8. Hold the weld nut securely in place. Use the MIG Wire Feed Welder 106-00053 to plug weld the nut in place at the two 8 mm (5/16 in) diameter holes previously drilled. 9. Metal finish as required. 10. Verify the nut is securely in place. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt <--> [Seat Belt] > Component Information > Service and Repair > Safety Belt Twisted At the Safety Belt Guide - Outboard > Page 8406 Safety Belt: Service and Repair Safety Belt Tongue Rotated on Belt 1. Fold the safety belt as indicated. 2. Pull the safety belt tongue over the fold in the safety belt. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Specifications Safety Belt Buckle: Specifications Driver Seat Safety Belt Buckle Bolt 34-46 Nm Driver Seat Safety Belt Buckle Nut 34-46 Nm Passenger Seat Safety Belt Buckle Bolt 34-46 Nm Quad Seat Safety Belt Buckle Bolt 34-46 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Service and Repair > Safety Belt Buckle - 40/60 Split Bench Seat, Center and RH Passenger, Front Seat Safety Belt Buckle: Service and Repair Safety Belt Buckle - 40/60 Split Bench Seat, Center and RH Passenger, Front Seat Torx Bit Tool Set Used For T55 "Torx Plus" Bit Special Service Tool(s) REMOVAL 1. Remove the front passenger safety belt. 1 Use T55 "Torx Plus" Bit to remove the bolt. 2 Feed the belt through the seat cushion pocket and remove the belt. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Service and Repair > Safety Belt Buckle - 40/60 Split Bench Seat, Center and RH Passenger, Front Seat > Page 8412 Safety Belt Buckle: Service and Repair Safety Belt Buckle - Captain's Chair Safety Belt Bolt Bit Special Service Tool(s) REMOVAL 1. Remove the front floor console. 2. Remove the passenger seat safety belt buckle. 1 Use Seat Belt Bolt Bit to remove the bolt. 2 Remove the buckle. 3. On power driver seats, remove the driver seat safety belt buckle. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Use Seat Belt Bolt Bit to remove the bolt. 3 Remove the buckle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Service and Repair > Safety Belt Buckle - 40/60 Split Bench Seat, Center and RH Passenger, Front Seat > Page 8413 4. On manual driver seats, remove the driver side safety belt buckle. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Remove the nut. 3 Remove the buckle. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Service and Repair > Safety Belt Buckle - 40/60 Split Bench Seat, Center and RH Passenger, Front Seat > Page 8414 Safety Belt Buckle: Service and Repair Safety Belt Buckle - 40/60 Split Bench, Driver Seat Safety Belt Bolt Bit Special Service Tool(s) REMOVAL 1. Remove the driver seat safety belt buckle. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Use Seat Belt Bolt Bit to remove the bolt. 3 Remove the buckle. NOTE: To ease removal, position the driver seat in its most rearward position and the passenger seat in its most forward position. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Service and Repair > Safety Belt Buckle - 40/60 Split Bench Seat, Center and RH Passenger, Front Seat > Page 8415 Safety Belt Buckle: Service and Repair Safety Belt Buckle - Quad Seat Safety Belt Bolt Bit Special Service Tool(s) REMOVAL 1. Position the seat forward. 2. Remove the safety belt buckle. 1 Use Seat Belt Bolt Bit to remove the bolt. 2 Remove the buckle. INSTALLATION 1. To install, reverse the removal procedure. ^ Check for proper operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Service and Repair > Safety Belt Buckle - 40/60 Split Bench Seat, Center and RH Passenger, Front Seat > Page 8416 Safety Belt Buckle: Service and Repair Safety Belt Buckle - 40/60 Split Bench Seat, Center and RH Passenger Safety Belt Bolt Bit Special Service Tool(s) REMOVAL 1. Remove the safety belt buckle assembly. 1 Use Seat Belt Bolt Bit to remove the two bolts. 2 Remove the assembly. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Safety Belt Buckle <--> [Seat Belt Buckle] > Component Information > Service and Repair > Safety Belt Buckle - 40/60 Split Bench Seat, Center and RH Passenger, Front Seat > Page 8417 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Extension > Component Information > Description and Operation Seat Belt Extension: Description and Operation In certain cases, the safety belt may be too short even when it is fully extended. About 20 cm (8 in) can be added to the belt length by using a safety belt extension. Safety belt extensions are available through any Ford or Lincoln Mercury dealer parts department at no cost. Safety belt extensions are only available with black webbing. There are two extension assemblies available one for the front seating positions and one for the rear seating positions. They are not interchangeable. Use only extensions manufactured by the same supplier as the safety belt. Manufacturer identification is located at the end of the webbing on the label. Also, use the safety belt extension only if the safety belt is too short for you when fully extended. Do not use extension to change the fit of the shoulder belt across the torso. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Specifications Seat Belt Height Adjuster: Specifications Safety Belt Height Adjuster 34-46 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal Installation Seat Belt Height Adjuster: Service and Repair Removal Installation Height Adjuster - Front Safety Belt Bolt Bit Special Service Tool(s) REMOVAL NOTE: This procedure is for the LH side; RH side is similar. 1. Remove the safety belt guide. 1 Lift the bolt cover from the bottom. 2 Remove the nut. 2. Remove the front door scuff plate. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal Installation > Page 8426 3. Remove the rear door scuff plate. 4. Remove the B-pillar assist handle. 1 Remove the two covers. 2 Remove the two screws. 3 Remove the B-pillar assist handle. 5. Position the B-pillar trim panel aside. ^ Remove the front and rear door weather seals. NOTE: Remove the upper attachments first, then the lower attachments. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal Installation > Page 8427 6. Use Seat Belt Bolt Bit to remove the safety belt anchor bolt. 7. Remove the height adjuster cover. 8. Remove the shoulder safety belt height adjuster. 1 Use Seat Belt Bolt Bit to remove the bolts. 2 Remove the adjuster. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal Installation > Page 8428 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. NOTE: Bolts should be started by hand. Height Adjuster - Second Row Seat Safety Belt Bolt Bit Special Service Tool(s) REMOVAL NOTE: This procedure is for the LH side; the RH side is similar. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal Installation > Page 8429 1. Remove the safety belt guide. 1 Lift the nut cover from the bottom. 2 Remove the nut. 2. Remove the C-pillar trim panel. NOTE: Remove upper attachments first, followed by the front lower attachment and the lower rear hook. 3. Remove the height adjuster cover. 4. Remove the shoulder safety belt height adjuster. 1 Use Seat Belt Bolt Bit to remove the bolts. 2 Remove the adjuster. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal Installation > Page 8430 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. NOTE: Bolts should be started by hand. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal Installation > Page 8431 Seat Belt Height Adjuster: Service and Repair General Procedures D-Ring Installation Kit Special Service Tool(s) 1. Remove the height adjuster. 2. Use the half-inch drill with integral stop provided in D-Ring Installation Kit to drill out the damaged threads in the upper pillar structure. 3. Apply a suitable lubricant to the M14 x 1.5 tap with integral stop provided in D-Ring Installation Kit and tap new threads. NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out any chips before proceeding. 4. Use a threaded insert (part number N807170-5190) provided in D-Ring Installation Kit and screw it into the retapped hole until it is slightly below the surface. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal Installation > Page 8432 5. Use a hammer to lightly tap the installation tool provided in D-Ring Installation Kit several times to seat the insert keys. NOTE: If the two bolts on the height adjuster are not stripped, refer to Height Adjuster-Front or Height Adjuster-Second Row Seat. If the bolts are stripped, replace the height adjuster. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Reminder Lamp > Component Information > Testing and Inspection Seat Belt Reminder Lamp: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract Seat Belt Retractor: Customer Interest Restraints - Seat Belts Slow to Retract TSB 05-16-11 08/22/05 SAFETY BELT RETRACTION SPEED FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2004-2006 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006 Monterey 2005-2006 Mariner This article supersedes TSB 04-24-21 to update the vehicle model years. ISSUE A service kit is now available to improve safety belt retraction speed. ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20A for additional information. NOTE TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE THREE VEHICLES. NOTE FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES. ^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on vehicles built on/after 6/16/2003. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract > Page 8444 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belts Slow to Retract TSB 05-16-11 08/22/05 SAFETY BELT RETRACTION SPEED FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2004-2006 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006 Monterey 2005-2006 Mariner This article supersedes TSB 04-24-21 to update the vehicle model years. ISSUE A service kit is now available to improve safety belt retraction speed. ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20A for additional information. NOTE TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE THREE VEHICLES. NOTE FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES. ^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on vehicles built on/after 6/16/2003. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts Slow to Retract > Page 8450 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 8451 Seat Belt Retractor: Specifications Safety Belt Retractor Bolt 34-46 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Technical Service Bulletins > Page 8452 Seat Belt Retractor: Description and Operation NOTE: When replacing an Automatic Locking Retraction (ALR) equipped retractor, the outboard retractors only, should be checked to make sure they are not in the ALR mode after installation. All outboard continuous-loop, three-point retractor systems, except the driver position, are equipped with the ALR system. This system is used when installing a child safety seat in an outboard seating position or when a tight lap/shoulder belt is desired by the occupant. The ALR system is automatically engaged when the webbing is fully extracted from the retractor. As the webbing is retracted back onto the spool, an audible clicking sound is made indicating the retractor is in the ALR mode. The ALR mode is automatically disengaged when most of the webbing is retracted back onto the spool. The ALR mode is disengaged when the audible clicking sound ceases and the webbing is free to move in or out of the retractor indicating a normal mode of operation. The automatic locking mode must be used when installing a child safety seat in the front passenger and rear outboard passenger seating positions where dual locking mode retractors are provided. The second row 60% portion of the 40/60 split bench seat center passenger retractor is equipped with ALR only. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Retractor - Front, Driver Side Seat Belt Retractor: Service and Repair Retractor - Front, Driver Side Safety Belt Bolt Bit Special Service Tool(s) REMOVAL NOTE: This procedure is for the LH side; the RH side is similar. 1. Remove the safety belt guide. 1 Lift the nut cover from the bottom. 2 Remove the nut. 2. Remove the front door scuff plate. 3. Remove the rear door scuff plate. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Retractor - Front, Driver Side > Page 8455 4. Remove the B-pillar assist handle. 1 Remove the two covers. 2 Remove the two screws. 3 Remove the B-pillar assist handle. 5. Position the B-pillar trim panel aside. ^ Remove the front and rear door weather seals. NOTE: Remove the upper attachments first, then the lower attachments. 6. Use Seat Belt Bolt Bit to remove the safety belt anchor bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Retractor - Front, Driver Side > Page 8456 7. Remove the front safety belt retractor. 1 Use Seat Belt Bolt Bit to remove the bolt. 2 Remove the retractor. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. NOTE: Before the retractor bolt is installed the retractor bracket should be aligned with the hole in the sheet metal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Retractor - Front, Driver Side > Page 8457 Seat Belt Retractor: Service and Repair Retractor - Second Row Seat, Driver Side Safety Belt Bolt Bit Special Service Tool(s) REMOVAL NOTE: This procedure is for the LH side; the RH side is similar. 1. Remove the safety belt guide. 1 Lift the nut cover from the bottom. 2 Remove the nut. 2. Remove the quarter trim panel. 3. Use Seat Belt Bolt Bit to remove the safety belt anchor bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Retractor - Front, Driver Side > Page 8458 4. Remove the center safety belt retractor. 1 Use Seat Belt Bolt Bit to remove the bolt. 2 Remove the retractor. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Retractor - Front, Driver Side > Page 8459 Seat Belt Retractor: Service and Repair Retractor - Third Row Safety Belt Bolt Bit Special Service Tool(s) REMOVAL NOTE: This procedure is for the LH side; the RH side is similar. 1. Remove the safety belt guide bolt cover. ^ Carefully pry out at the bottom. 2. Use Seat Belt Bolt Bit to remove the safety belt guide bolt. 3. Remove the quarter trim panel. NOTE: On vehicles equipped with auxiliary A/C, only the auxiliary A/C access panel needs to be removed and not the quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Retractor - Front, Driver Side > Page 8460 4. Remove the detachable anchor. ^ Depress the release button. 5. Remove the rear safety belt retractor. 1 Use Seat Belt Bolt Bit to remove the bolt. 2 Remove the retractor. 6. Remove the detachable anchor tongue trim cover. 1 Remove the bolt. 2 Remove the pushpin. 3 Remove the trim cover. NOTE: Steps six and seven are only necessary if the detachable anchor tongue has to be replaced. 7. Remove the detachable anchor tongue. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Retractor > Component Information > Service and Repair > Retractor - Front, Driver Side > Page 8461 1 Use Seat Belt Bolt Bit to remove the bolt. 2 Remove the detachable anchor tongue. INSTALLATION 1. To install, reverse the removal procedure. ^ Check the restraint system for proper operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation Seat Belt Warning Relay: Technical Service Bulletins Seat Belts - Warning System Operation Article No. 01-2-5 2/05/01 ^ TRIM - SEAT BELT WARNING SYSTEM - "BELT ^ MINDER" FUNCTION - OPERATION AND SERVICE ^ TIPS ^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND ^ SERVICE TIPS FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION, F-150, RANGER, WINDSTAR 2001 EXPLORER LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER ISSUE The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the instrument cluster. ACTION Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following Service Procedure. SERVICE PROCEDURE To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure. 1. Establish a session for the vehicle. 2. Select the "Toolbox" icon. 3. Select "Module Programming" and press the "Tick" mark. 4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark. 5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark. 6. WDS will display "Configuration Complete", then press the "Tick" mark. NOTE: IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE SAFETY BELT IS BUCKLED. NOTE: WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND FOR 4-8 SECONDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Warning Relay > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation > Page 8466 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 104000, 204000, 206000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Warning Timer > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation Seat Belt Warning Timer: Technical Service Bulletins Seat Belts - Warning System Operation Article No. 01-2-5 2/05/01 ^ TRIM - SEAT BELT WARNING SYSTEM - "BELT ^ MINDER" FUNCTION - OPERATION AND SERVICE ^ TIPS ^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND ^ SERVICE TIPS FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION, F-150, RANGER, WINDSTAR 2001 EXPLORER LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER ISSUE The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the instrument cluster. ACTION Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following Service Procedure. SERVICE PROCEDURE To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure. 1. Establish a session for the vehicle. 2. Select the "Toolbox" icon. 3. Select "Module Programming" and press the "Tick" mark. 4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark. 5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark. 6. WDS will display "Configuration Complete", then press the "Tick" mark. NOTE: IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE SAFETY BELT IS BUCKLED. NOTE: WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND FOR 4-8 SECONDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Safety Belt Systems <--> [Seat Belt Systems] > Seat Belt Warning Timer > Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation > Page 8471 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 104000, 204000, 206000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Specifications Impact Sensor: Specifications Side Crash Sensor Screws 12 Nm Restraint Control Module (RCM) Bracket Screws 12 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor Impact Sensor: Locations Driver Side Air Bag Crash Sensor Near driver seat. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 8478 Impact Sensor: Locations Passenger Side Air Bag Crash Sensor Near passenger seat. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 8479 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 8480 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 8481 Impact Sensor: Service and Repair REMOVAL AND INSTALLATION WARNING: ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. ^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. ^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). NOTE: ^ Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. ^ Right side is shown, left side is similar. ^ The side crash sensors are located under the carpet beneath the front seats. 1. Disconnect the battery ground cable and wait at least one minute. 2. Position the side crash sensor out from under the seat. 1 Pull the carpet flap out from under the outboard side of the seat to expose the side crash sensor. 2 Remove the pin-type retainer. 3 Remove the bolts. 4 Position the side crash sensor out from under the seat. NOTE: A flap opening in the carpet, at the outboard side of the front seats already exists, for servicing the side crash sensor. 3. Remove the side crash sensor. 1 Disconnect the electrical connector. 2 Remove the side crash sensor and bracket. 4. To install, reverse the removal procedure. WARNING: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 8482 ^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED. ^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS CRITICAL FOR CORRECT SYSTEM OPERATION. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 5. Prove out the air bag system. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Safing Sensor, Air Bag > Component Information > Description and Operation Safing Sensor: Description and Operation The safing sensor is internal to the Restraints Control Module (RCM) and is not repaired separately. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8491 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8492 Accessory Delay Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Service and Repair Antenna, Navigation: Service and Repair Navigation Antenna REMOVAL 1. Disconnect the battery. For additional information, refer to Battery. 2. Remove the instrument panel relay panel. Refer to Dash Board. 3. Remove the antenna. 1 Disconnect the cable. 2 Remove the GPS antenna. ^ Clean any remaining glue from the instrument panel surface. NOTE: The GPS antenna is secured to the instrument panel with two-sided tape. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Front Antenna Cable: Service and Repair Front REMOVAL 1. Remove the RH scuff plate. 2. Remove the RH A-pillar lower trim panel. 3. Disconnect the two pin-type retainers from the lower A-pillar. 4. Disconnect the rear antenna lead-in cable from the front antenna lead-in cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Front > Page 8502 5. Remove the front antenna lead-in cable. 1 Disconnect the pin-type retainers from the lower Instrument Panel (I/P) channel. 2 Remove the front antenna lead-in cable from the I/P. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Front > Page 8503 Antenna Cable: Service and Repair Rear REMOVAL 1. Remove the RH scuff plate. 2. Remove the RH A-pillar lower trim panel. 3. Disconnect the rear antenna lead-in cable from the front antenna lead-in cable. 4. Remove the RH rear door scuff plate. 5. Remove the RH rear quarter trim. 6. Lower the headliner enough to gain access to the rear antenna cable connection. 7. Disconnect the rear lead-in cable from the antenna cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Front > Page 8504 8. Remove the nut from the ground plate. 9. Remove the ground plate and remove the antenna cable ends. NOTE: The antenna is an integral part of the wiring harness and can not be replaced separately from the harness. Cut the ends off of the old antenna cable and tape the remainder to the wiring harness to prevent noise. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When installing the new cable, tape or wire tie the new cable to the wiring harness to prevent noise. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Passive Anti-Theft System Transceiver Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Passive Anti-Theft System Transceiver Module > Page 8510 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Passive Anti-Theft System Transceiver Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Passive Anti-Theft System Transceiver Module > Page 8513 Alarm Module: Diagrams Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Locations > Page 8517 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Locations > Page 8518 Alarm System Transponder: Service and Repair REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pushing out the ignition switch lock cylinder. 3. Unscrew and remove the tilt wheel handle and shank. 4. Remove the instrument panel steering column cover. For additional information, refer to Dash Board. 5. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. NOTE: The steering wheel has been removed for clarity. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Locations > Page 8519 6. Remove the anti-theft transceiver module. 1 Remove the screw from the bottom of the transceiver module. 2 Disconnect the electrical connector and remove the module. NOTE: Only apply pressure or leverage below the key cylinder lower rib. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics TSB 06-15-8 08/07/06 KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005 Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006 Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006 F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan 1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to properly diagnose the concern with the keyless entry keypad, it is important to identify whether the keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF) style keypad. ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic service tips. SERVICE PROCEDURE IDENTIFICATION: 1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and are wired directly to the module controlling the vehicle's keyless entry system. This style keypad can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 8525 2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13 mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM (Figure 1). NOTE THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD DIAGNOSTICS FOR THESE VEHICLES. GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS 1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed using a similar procedure. Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter programming portion of the WSM, Section 501-14 can be used as a guide NOTE THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN ADDITIONAL REMOTE TRANSMITTER. Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the lock / unlock functions will differ 2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced separately. 3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super Duty vehicles produced prior to 12/3/2003). 4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM etc.) is replaced. NOTE THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE. 5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all doors). The keypad contains an optical sensor and will not illuminate under bright lighting conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the battery power available to transmit a lock/unlock signal. The temperature at which this occurs will vary depending upon the keypad battery age and condition. Both of these conditions are a normal function of the Power Save Mode and do not indicate a need to replace the keypad. 6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication that battery power is very low and the keypad must be replaced. 7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35 consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash during this time. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 8526 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 8527 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 8528 Keyless Entry Key-Pad: Service and Repair REMOVAL 1. Remove the driver door trim panel. 2. Remove the keyless entry keypad. 1 Remove the screw. 2 Remove the speed ruts. 3 Remove the keyless entry keypad. ^ Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Testing and Inspection Keyless Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Keyless Entry; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Testing and Inspection > Page 8532 Keyless Entry Module: Service and Repair RAP/General Module REMOVAL AND INSTALLATION For additional information, refer to Multifunction Electronic Control Modules (General Module). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Service and Repair Cellular Phone Microphone: Service and Repair REMOVAL 1. Remove the air bag sliding contact. For additional information, refer to Air Bag Systems. 2. Remove the cellular phone microphone from the air bag sliding contact. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Diagrams > Page 8541 Parking Assist Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Collision Avoidance and Parking Assist Systems; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Diagrams > Page 8542 Parking Assist Control Module: Service and Repair REMOVAL 1. Remove the RH C-pillar trim panel. 2. Remove the Parking Aid Module (PAM). 1 Disconnect the electrical connectors. 2 Remove the screws. 3 Remove the PAM. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Specifications Parking Assist Distance Sensor: Specifications Azimuth System Check Object Position 1 (P1) And Position 5 (P5), Distance From Sensor 30.48 cm Azimuth System Check Object Position 2 (P2) And Position 4 (P4) , Distance From Sensor 91.44 cm Azimuth System Check Object Position 3 (P3), Distance From Sensor 152.4 cm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Left Center Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Left Center Sensor > Page 8548 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Left Center Sensor > Page 8549 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Left Center Sensor > Page 8550 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Page 8551 Parking Assist Distance Sensor: Service and Repair REMOVAL 1. Remove the parking aid sensor. 1 Disconnect the electrical connector. 2 Release the tabs. 3 Remove the parking aid sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Switch > Component Information > Diagrams > Page 8555 Parking Assist Switch: Service and Repair REMOVAL 1. Remove the front floor console finish panel. For additional information, refer to Console. 2. Remove the parking aid switch. ^ Release the tabs. ^ Remove the parking aid switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation Driver/Vehicle Information Display: Description and Operation NOTE: ^ The Distance To Empty (DTE) display may be inaccurate if the vehicle is started while parked on an incline. ^ Fuel fills of less than 22.7 liters (6 gallons) may not be detected by the message center. ^ The instantaneous (INST) fuel economy feature is only available on early production vehicles. The message center uses inputs from the fuel level sensor and pump, the compass sensor module and the Powertrain Control Module (PCM). The input from the PCM is the vehicle speed signal. The PCM gets the vehicle speed signal from the Output Shaft Speed (OSS) sensor. From those inputs, the message center displays: ^ compass direction. ^ DTE. ^ average (AVG) fuel economy. ^ INST fuel economy (if equipped). Average (AVG) Fuel Economy - Resetting NOTE: Only the AVG fuel economy can be reset. DTE and INST displays cannot be reset. The AVG fuel economy display is resettable. To reset, the ignition switch must be in the RUN position (with or without the engine running) and the message center must be in the AVG fuel economy display mode. Press and release the MODE and E/M buttons simultaneously. If the vehicle is parked while resetting, the AVG fuel economy will display 0.0 (English mode) or 99.9 (metric mode). If the vehicle is in motion, the AVG fuel economy will display the current INST fuel economy (English mode or metric mode). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 8559 Driver/Vehicle Information Display: Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center Assembly Driver/Vehicle Information Display: Service and Repair Message Center Assembly REMOVAL 1. Open the overhead sunglasses compartment and remove the screw. 2. Grasp the front of the overhead console and pull down to remove the console. 3. Disconnect the electrical connectors. 4. Remove the message center. 1 Depress the lock tab underneath the in-line electrical connector. 2 Remove the in-line connector. 3 Remove the screws. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center Assembly > Page 8562 4 Remove the message center. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center Assembly > Page 8563 Driver/Vehicle Information Display: Service and Repair Vehicle Demagnetizing 1. CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a cloth over the vehicle's roof to protect the vehicle's surface if contact occurs. Make sure the cloth covers the front third and the entire width of the roof. NOTE: ^ The demagnetizing process requires the use of a demagnetizing coil commonly used by television service technicians to demagnetize television tubes. ^ To demagnetize, use a constant circular motion over the vehicle's roof. Do not turn off the demagnetizer while sweeping the vehicle's roof to prevent remagnetizing ferrous materials contained in the vehicle. ^ During the demagnetizing process, make sure the phenolic surface of the tool (the side opposite the handle) is closest to the vehicle's surface. 2. Demagnetize the front third of the vehicle's roof. 1 Turn on the demagnetizer at least 1 meter (3 ft) away from the vehicle. 2 Holding the demagnetizer no more than 2.5 cm (1 in) from the roof and starting on the passenger side, demagnetize the front third of the roof closest to the windshield using a constant circular motion. Keep the circle's radius within 30 cm (12 in) while sweeping across the entire surface of the roof closest to the windshield. Continue the circular motion four times. 3 After the fourth pass and without stopping, move the demagnetizer at least 1 meter (3 ft) away from the vehicle. 4 Turn the demagnetizer off. 3. Demagnetize the inside rear view mirror mounting pad. NOTE: The demagnetizer must be located over the outside of the windshield no greater than 2.5 cm (1 in). 1 Turn on the demagnetizer at least 1 meter (3 ft) away from the vehicle. 2 Using a circular motion, pass the demagnetizer over the outside of the windshield near the inside rear view mirror mounting pad. Without stopping, move the demagnetizer at least 1 meter (3 ft) away from the vehicle. 3 Turn the demagnetizer off. 4. Carry out the Compass Zone Adjustment procedure; refer to Compass Zone Adjustment. See: Instrument Panel, Gauges and Warning Indicators/Compass/Adjustments/Compass Zone Adjustment 5. Carry out the Calibration Adjustment procedure; refer to Calibration Adjustment. See: Instrument Panel, Gauges and Warning Indicators/Compass/Adjustments/Calibration Adjustment Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 8564 Special Service Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation Garage Door Opener Transmitter: Description and Operation The HomeLink(R) universal transmitter provides a convenient way to replace up to three hand-held transmitters with a single built-in device. The universal transmitter: ^ will operate garage doors, gates and home/office lighting and security systems. ^ will actually learn and transmit the radio frequency of up to three hand-held transmitters from any of the Systems mentioned above. ^ is an integral part of the left sun visor assembly and is powered by the vehicle battery and charging system. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged universal transmitter ^ Damaged receiver 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the fault is not visually evident, verify the symptom and refer to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8570 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8571 Garage Door Opener Transmitter: Pinpoint Tests Connector Circuit Reference Refer to the Vehicle/Diagrams for schematic and connector information. A1 - A2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Programming The Universal Transmitter Garage Door Opener Transmitter: Service and Repair Programming The Universal Transmitter Programming The Universal Transmitter WARNING: A GARAGE DOOR OPENING SYSTEM THAT CANNOT STOP OR REVERSE ITSELF AFTER DETECTING AN OBJECT IN ITS PATH DOES NOT MEET CURRENT FEDERAL SAFETY STANDARDS. TO DECREASE THE RISK OF SERIOUS INJURY OR DEATH, DO NOT USE THIS HOMELINK(R) TRANSMITTER WITH A DOOR OPENING SYSTEM THAT LACKS STOP AND REVERSE FEATURES AS REQUIRED BY FEDERAL STANDARDS. THIS INCLUDES ANY GARAGE DOOR OPENING SYSTEM MANUFACTURED BEFORE APRIL 1,1982. FOR MORE INFORMATION, CALL HOMELINK(R) CUSTOMER ASSISTANCE AT 1-800-355-3515. 1. Verify the hand-held transmitter is operative. CAUTION: During this procedure, the system that you are programming will be made to operate. Make sure that people or objects are clear of the garage door or gate being programmed. 2. Prepare for programming the universal transmitter by erasing all three channels by holding down the two outside buttons until the red light begins to flash (20-30 seconds). Release both buttons. 3. Select one of the three universal transmitter channels to be programmed by pressing the desired button. 4. Hold the end of the hand-held transmitter 25-51 mm (1-2 in) from the front surface of the universal transmitter so that the red light can still be seen. 5. Use both hands to press the hand-held transmitter button and the desired button on the universal transmitter. Do not release either button. NOTE: During programming, the hand-held transmitter may automatically stop transmitting after two seconds, which may not be long enough to program the universal transmitter. If programming this type of hand-held transmitter, continue to hold the button on the universal transmitter while re-pressing the hand-held transmitter button every two seconds (Canada only). 6. Hold down both buttons until the red light on the universal transmitter flashes, first slowly and then rapidly. Release both buttons when the rapid flashing begins. The universal transmitter has successfully learned the new frequency signal and can be used in place of the hand-held transmitter(s). 7. To operate, simply press the appropriate button on the universal transmitter. The red light is on while the signal is being transmitted. NOTE: If the hand-held transmitter appears to program the universal transmitter but does not open the garage door, the garage door opener may have a "code protected" or "rolling code" feature. Training a Garage Door Opener Equipped With "Rolling Codes" 1. Program the hand-held transmitter to the universal transmitter; for additional information, refer to Programming. 2. Train the garage door opener receiver to recognize the universal transmitter. 1 Remove the cover panel from the garage door opener receiver. 2 Locate the training button on the garage door opener receiver. Location and color of the button may vary by garage door opener manufacturer. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Programming The Universal Transmitter > Page 8574 Refer to the garage door opener instruction manual or call HomeLink(R) customer assistance at 1-800-355-3515. 3 Press the training button on the garage door opener receiver for 1-2 seconds. 4 Press the programmed universal transmitter button for as long as the universal transmitter red light flashes (1-2 seconds). Release the button and re-press the button to confirm that the universal transmitter is trained to the receiver. 5 The garage door opener should recognize the universal transmitter. Erasing Channels 1. To erase all three programmed channels, hold down the two outside buttons until the red light begins to flash (20-30 seconds). Release both buttons. NOTE: Individual channels cannot be erased, but can be reprogrammed using the procedures for programming; for additional information, refer to Programming. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Programming The Universal Transmitter > Page 8575 Garage Door Opener Transmitter: Service and Repair Training A Garage Door Opener Training a Garage Door Opener Equipped With "Rolling Codes" 1. Program the hand-held transmitter to the universal transmitter; for additional information, refer to Programming The Universal Transmitter. 2. Train the garage door opener receiver to recognize the universal transmitter. 1 Remove the cover panel from the garage door opener receiver. 2 Locate the training button on the garage door opener receiver. Location and color of the button may vary by garage door opener manufacturer. Refer to the garage door opener instruction manual or call HomeLink(R) customer assistance at 1-800-355-3515. 3 Press the training button on the garage door opener receiver for 1-2 seconds. 4 Press the programmed universal transmitter button for as long as the universal transmitter red light flashes (1-2 seconds). Release the button and re-press the button to confirm that the universal transmitter is trained to the receiver. 5 The garage door opener should recognize the universal transmitter. Erasing Channels 1. To erase all three programmed channels, hold down the two outside buttons until the red light begins to flash (20-30 seconds). Release both buttons. NOTE: Individual channels cannot be erased, but can be reprogrammed using the procedures for programming; for additional information, refer to Programming The Universal Transmitter. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications Multifunction Electronic Control Modules: Specifications Remote Anti-Theft Personality (RAP) Module Nuts 7 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications > Page 8579 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8582 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8583 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8584 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8585 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8586 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8587 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8588 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8589 Multifunction Electronic Control Modules: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8590 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8591 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8592 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8593 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8594 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8595 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8596 Multifunction Electronic Control Modules: Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8597 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8598 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8599 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 59-1 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8600 Diagram 59-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8601 Diagram 59-3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8602 Diagram 59-4 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8603 Diagram 59-5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 8604 Multifunction Electronic Control Modules: Service Precautions CAUTION: ^ Prior to removal of module, it is necessary to upload module configuration information to scan tool. This information needs to be downloaded into the new module once installed. For additional information; refer to Module Communications Network. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. ^ Once the new module is installed it is necessary to download the module configuration information from the scan tool into the new module. For additional information; refer to Module Communications Network. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > GEM Feature Matrix Multifunction Electronic Control Modules: Description and Operation GEM Feature Matrix Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > GEM Feature Matrix > Page 8607 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > GEM Feature Matrix > Page 8608 Multifunction Electronic Control Modules: Description and Operation Module Controlled Functions Module Controlled Functions The multi function modules consist of the following: ^ Generic Electronic Module (GEM) The generic electronic module (GEM) constantly monitors its subsystems for concerns. If a concern is found in one of the subsystems, the GEM will record the concern in the form of a Diagnostic Trouble Code (DTC). The ignition switch position is very important to the GEM function. Often times, erratic or unexpected GEM function can be traced to problems with these GEM inputs. The GEM controls the following features: ^ Wipers/washers (front/rear). ^ Warning chimes. ^ Battery saver. ^ Illuminated entry and courtesy lamps. ^ Driver power window. ^ Accessory delay. ^ 4-wheel drive. ^ Heated backlite/mirror. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > Page 8609 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Remote Anti-Theft Personality (RAP) Module Multifunction Electronic Control Modules: Service and Repair Remote Anti-Theft Personality (RAP) Module REMOVAL 1. Disconnect the battery ground cable. CAUTION: ^ Prior to removal of module, it is necessary to upload module configuration information to scan tool. This information needs to be downloaded into the new module once installed. For additional information; refer to Module Communications Network. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Disconnect the Remote Anti-Theft Personality (RAP) module electrical connectors. 3. Remove the nuts and the RAP module. NOTE: On Expedition and later build Navigators, the antenna is internal to the module and must be replaced as an assembly. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Once the new module is installed it is necessary to download the module configuration information from the scan tool into the new module. For additional information; refer to Module Communications Network. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Remote Anti-Theft Personality (RAP) Module > Page 8612 Multifunction Electronic Control Modules: Service and Repair Module-Generic Electronic (GEM) REMOVAL 1. Disconnect the battery ground cable. CAUTION: ^ Prior to removal of the module, it is necessary to upload module configuration information to scan tool. This information needs to be downloaded into the new module once installed. For additional information, refer to Module Communications Network. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the steering column cover. For additional information, refer to Dash Board. 3. Remove the (A) bulkhead electrical connectors from the (B) instrument panel fuse junction panel. 4. Remove the (A) instrument panel fuse junction panel bolts and remove the (B) interior fuse junction panel nuts. 5. Disconnect the (A) Generic Electronic Module (GEM) electrical connectors from the (B) GEM. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Remote Anti-Theft Personality (RAP) Module > Page 8613 6. Remove the screws and the GEM. INSTALLATION 1. To install, reverse the removal procedure. ^ Check for proper operation. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the scan tool into the new module. For additional information, refer to Module Communications Network. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Remote Anti-Theft Personality (RAP) Module > Page 8614 Multifunction Electronic Control Modules: Service and Repair Module-Driver Seat REMOVAL 1. If exposed to these charges, damage may result. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. 2. Remove the driver seat. For additional information, refer to Seats. 3. Disconnect the driver seat module electrical connectors. 4. Remove the screws from the Driver Seat Module (DSM) and release the module retainers from the module bracket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Testing and Inspection Global Positioning System Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Navigation System; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Locations > Page 8627 Navigation Module: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Locations > Page 8628 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Service and Repair > Navigation System Display Module Navigation Module: Service and Repair Navigation System Display Module REMOVAL 1. Disconnect the battery. For additional information, refer to Battery. 2. Remove the screw. 3. Carefully pull up on the console finish panel and unsnap it from the center console. 4. Disconnect the harness connectors and parking aid switch (if equipped) and remove the console finish panel. 5. Remove the screws and remove the navigation system display module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Service and Repair > Navigation System Display Module > Page 8631 Navigation Module: Service and Repair Navigation System Module REMOVAL 1. Disconnect the battery. Refer to Battery. 2. Remove the lower screws. Unsnap and remove the CD-DJ and Navigation System Module (NSM) cover. 3. Remove the upper screws. 4. Slide the NSM up out of the console, disconnect the three harness connectors and GPS antenna cable and remove the NSM. NOTE: The GPS antenna cable is attached to the NSM with a locking sleeve on the connector Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Service and Repair > Navigation System Display Module > Page 8632 5. Remove the two screws on each end of the bracket and remove the NSM. INSTALLATION 1. To install, reverse the removal procedure. ^ Make sure all connectors are correctly locked. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 8637 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Page 8642 CD Changer: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the mat at bottom the of the console bin and remove the screws. ^ To ease removal of the trim panel, pull the front edge back and lift out. 3. Remove the screws and pull out the CD changer and bracket. 4. Disconnect the electrical connector. 5. Remove the screws. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8652 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8653 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8654 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8655 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8656 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8657 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8658 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8664 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8665 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8666 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8667 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8668 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8669 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8670 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 8671 Radio/Stereo Noise Filter: Specifications Radio frequency interference suppression bond to bulkhead screw 12 Nm Radio frequency interference suppression bond to engine nut 11 Nm Radio frequency interference suppression bond frame to floorpan screws 12 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the cellular phone holder (if equipped). 1 Remove the screws. 2 Remove the cellular phone holder. 3. Remove the center console lid. 1 Remove the screws. 2 Remove the center console lid. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Service and Repair > Page 8675 4. Disconnect the console rear panel. 1 Remove the upper screws. 2 Lower the cup holder. 3 Remove the four rear screws. 5. Remove the rear integrated control panel. 1 If equipped, disconnect the floor/panel control cable at the control head. 2 Disconnect the power point electrical connector. 3 If equipped, disconnect the blower motor control electrical connector. 4 Disconnect the radio control electrical connector. 5 Remove five screws. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers Speaker: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8684 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8685 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8686 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8687 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8688 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8689 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 8690 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Speaker: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8696 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8697 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8698 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8699 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8700 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8701 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 8702 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 8703 Speaker: Specifications Speaker Screws 3 Nm Subwoofer Enclosure Screws 6 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 8704 Speaker: Description and Operation ^ The rear radio speakers are located behind the rear door trim panels. ^ The front radio speakers are located behind the front door trim panels. ^ The subwoofer is located behind the RH quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 8705 Speaker: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the speaker. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8711 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8712 Accessory Delay Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Passive Anti-Theft System Transceiver Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Passive Anti-Theft System Transceiver Module > Page 8717 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Passive Anti-Theft System Transceiver Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Passive Anti-Theft System Transceiver Module > Page 8720 Alarm Module: Diagrams Remote Anti-Theft Personality Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications Multifunction Electronic Control Modules: Specifications Remote Anti-Theft Personality (RAP) Module Nuts 7 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications > Page 8724 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions Multifunction Electronic Control Modules: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8727 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8728 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8729 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8730 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8731 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8732 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8733 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8734 Multifunction Electronic Control Modules: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8735 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8736 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8737 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8738 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8739 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8740 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8741 Multifunction Electronic Control Modules: Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8742 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8743 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8744 Multifunction Electronic Control Modules: Electrical Diagrams Diagram 59-1 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8745 Diagram 59-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8746 Diagram 59-3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8747 Diagram 59-4 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 8748 Diagram 59-5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 8749 Multifunction Electronic Control Modules: Service Precautions CAUTION: ^ Prior to removal of module, it is necessary to upload module configuration information to scan tool. This information needs to be downloaded into the new module once installed. For additional information; refer to Module Communications Network. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. ^ Once the new module is installed it is necessary to download the module configuration information from the scan tool into the new module. For additional information; refer to Module Communications Network. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > GEM Feature Matrix Multifunction Electronic Control Modules: Description and Operation GEM Feature Matrix Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > GEM Feature Matrix > Page 8752 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > GEM Feature Matrix > Page 8753 Multifunction Electronic Control Modules: Description and Operation Module Controlled Functions Module Controlled Functions The multi function modules consist of the following: ^ Generic Electronic Module (GEM) The generic electronic module (GEM) constantly monitors its subsystems for concerns. If a concern is found in one of the subsystems, the GEM will record the concern in the form of a Diagnostic Trouble Code (DTC). The ignition switch position is very important to the GEM function. Often times, erratic or unexpected GEM function can be traced to problems with these GEM inputs. The GEM controls the following features: ^ Wipers/washers (front/rear). ^ Warning chimes. ^ Battery saver. ^ Illuminated entry and courtesy lamps. ^ Driver power window. ^ Accessory delay. ^ 4-wheel drive. ^ Heated backlite/mirror. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Description and Operation > Page 8754 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Remote Anti-Theft Personality (RAP) Module Multifunction Electronic Control Modules: Service and Repair Remote Anti-Theft Personality (RAP) Module REMOVAL 1. Disconnect the battery ground cable. CAUTION: ^ Prior to removal of module, it is necessary to upload module configuration information to scan tool. This information needs to be downloaded into the new module once installed. For additional information; refer to Module Communications Network. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Disconnect the Remote Anti-Theft Personality (RAP) module electrical connectors. 3. Remove the nuts and the RAP module. NOTE: On Expedition and later build Navigators, the antenna is internal to the module and must be replaced as an assembly. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: Once the new module is installed it is necessary to download the module configuration information from the scan tool into the new module. For additional information; refer to Module Communications Network. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Remote Anti-Theft Personality (RAP) Module > Page 8757 Multifunction Electronic Control Modules: Service and Repair Module-Generic Electronic (GEM) REMOVAL 1. Disconnect the battery ground cable. CAUTION: ^ Prior to removal of the module, it is necessary to upload module configuration information to scan tool. This information needs to be downloaded into the new module once installed. For additional information, refer to Module Communications Network. ^ Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the steering column cover. For additional information, refer to Dash Board. 3. Remove the (A) bulkhead electrical connectors from the (B) instrument panel fuse junction panel. 4. Remove the (A) instrument panel fuse junction panel bolts and remove the (B) interior fuse junction panel nuts. 5. Disconnect the (A) Generic Electronic Module (GEM) electrical connectors from the (B) GEM. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Remote Anti-Theft Personality (RAP) Module > Page 8758 6. Remove the screws and the GEM. INSTALLATION 1. To install, reverse the removal procedure. ^ Check for proper operation. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the scan tool into the new module. For additional information, refer to Module Communications Network. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Remote Anti-Theft Personality (RAP) Module > Page 8759 Multifunction Electronic Control Modules: Service and Repair Module-Driver Seat REMOVAL 1. If exposed to these charges, damage may result. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. 2. Remove the driver seat. For additional information, refer to Seats. 3. Disconnect the driver seat module electrical connectors. 4. Remove the screws from the Driver Seat Module (DSM) and release the module retainers from the module bracket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Testing and Inspection Global Positioning System Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Navigation System; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Testing and Inspection Keyless Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Keyless Entry; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Testing and Inspection > Page 8766 Keyless Entry Module: Service and Repair RAP/General Module REMOVAL AND INSTALLATION For additional information, refer to Multifunction Electronic Control Modules (General Module). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Locations > Page 8770 Navigation Module: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Locations > Page 8771 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Service and Repair > Navigation System Display Module Navigation Module: Service and Repair Navigation System Display Module REMOVAL 1. Disconnect the battery. For additional information, refer to Battery. 2. Remove the screw. 3. Carefully pull up on the console finish panel and unsnap it from the center console. 4. Disconnect the harness connectors and parking aid switch (if equipped) and remove the console finish panel. 5. Remove the screws and remove the navigation system display module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Service and Repair > Navigation System Display Module > Page 8774 Navigation Module: Service and Repair Navigation System Module REMOVAL 1. Disconnect the battery. Refer to Battery. 2. Remove the lower screws. Unsnap and remove the CD-DJ and Navigation System Module (NSM) cover. 3. Remove the upper screws. 4. Slide the NSM up out of the console, disconnect the three harness connectors and GPS antenna cable and remove the NSM. NOTE: The GPS antenna cable is attached to the NSM with a locking sleeve on the connector Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Service and Repair > Navigation System Display Module > Page 8775 5. Remove the two screws on each end of the bracket and remove the NSM. INSTALLATION 1. To install, reverse the removal procedure. ^ Make sure all connectors are correctly locked. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Page 8779 Parking Assist Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Collision Avoidance and Parking Assist Systems; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Page 8780 Parking Assist Control Module: Service and Repair REMOVAL 1. Remove the RH C-pillar trim panel. 2. Remove the Parking Aid Module (PAM). 1 Disconnect the electrical connectors. 2 Remove the screws. 3 Remove the PAM. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Specifications Parking Assist Distance Sensor: Specifications Azimuth System Check Object Position 1 (P1) And Position 5 (P5), Distance From Sensor 30.48 cm Azimuth System Check Object Position 2 (P2) And Position 4 (P4) , Distance From Sensor 91.44 cm Azimuth System Check Object Position 3 (P3), Distance From Sensor 152.4 cm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Left Center Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Left Center Sensor > Page 8787 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Left Center Sensor > Page 8788 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Left Center Sensor > Page 8789 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Page 8790 Parking Assist Distance Sensor: Service and Repair REMOVAL 1. Remove the parking aid sensor. 1 Disconnect the electrical connector. 2 Release the tabs. 3 Remove the parking aid sensor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Switch > Component Information > Diagrams > Page 8794 Parking Assist Switch: Service and Repair REMOVAL 1. Remove the front floor console finish panel. For additional information, refer to Console. 2. Remove the parking aid switch. ^ Release the tabs. ^ Remove the parking aid switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8800 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8801 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8802 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8803 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8804 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8805 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8806 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8807 Trailer Connector: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8808 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8809 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8810 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8811 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8812 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8813 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8814 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8815 Trailer Connector: Electrical Diagrams Diagram 95-1 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8816 Diagram 95-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8817 Diagram 95-3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement Technical Service Bulletin # 00S05 Date: 000501 Recall - Trailer Hitch Hardware Replacement 00S05 SAFETY RECALL All 1997-2000 Model Year Expedition and Navigator with Trailer Hitch Package - Hitch Attachment ^ Original - May, 2000 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Notification Letter ^ Supplement # 1 - May, 2000 Aftermarket Hitch Kits and Existing Dealer Stock Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8826 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8827 Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instruction on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Attachment II Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8828 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts wilt not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information shown. SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III AFFECTED VEHICLES: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8829 CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8830 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8831 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8832 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8833 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8834 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8835 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8836 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8837 Supplement # 1 - Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT (I )Immediately contact any affected owner whose name is not on the list Give the owner a copy of the Owner Letter and schedule a service date. This contact includes owners who have purchased aftermarket hitch kit # F75Z-17D826-AE. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8838 REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Supplement # 1 - Attachment II LABOR ALLOWANCES PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8839 Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown above. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information above: SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. (I )REWORK OF EXISTING DEALER STOCK Call the Recall Hotline at 1-800-325-5621,to obtain instructions for reworking existing stock of Trailer Hitch Kits (part # F75Z-17D826-AE). NOTE: The Recall Hotline will provide new hardware and kit installation instructions.When you rework dealer stock, please make sure these revised instructions (with new torque specifications) are included in the kit. DEALER PRICE For latest prices, refer to: ^ DOESII ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Supplement # 1 - Attachment III HITCH ATTACHING FASTENER REPLACEMENT AFFECTED VEHICLES: CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8840 SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8841 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch. ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8842 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8843 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8844 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8845 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls: > NHTSA00V073000 > Mar > 00 > Recall 00V073000: Trailer Hitch Attaching Bolts Loose Trailer Hitch: Recalls Recall 00V073000: Trailer Hitch Attaching Bolts Loose Vehicle Description: Multi-purpose vehicles. The trailer hitch assembly to the frame attaching bolts could lose the clamp load. The trailer hitch could then separate from the vehicle. Dealers will replace the trailer hitch mounting bolts and nut plates. Owner notification began May 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1997 FORD TRUCK EXPEDITION 1997 LINCOLN TRUCK NAVIGATOR 1998 FORD TRUCK EXPEDITION 1998 LINCOLN TRUCK NAVIGATOR 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR 2000 FORD TRUCK EXPEDITION 2000 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Component Information > Diagrams > 4R70W Transmission Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > Component Information > Diagrams > 4R70W Transmission > Page 8854 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement Technical Service Bulletin # 00S05 Date: 000501 Recall - Trailer Hitch Hardware Replacement 00S05 SAFETY RECALL All 1997-2000 Model Year Expedition and Navigator with Trailer Hitch Package - Hitch Attachment ^ Original - May, 2000 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Notification Letter ^ Supplement # 1 - May, 2000 Aftermarket Hitch Kits and Existing Dealer Stock Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8864 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8865 Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instruction on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Attachment II Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8866 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts wilt not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information shown. SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III AFFECTED VEHICLES: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8867 CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8868 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8869 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8870 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8871 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8872 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8873 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8874 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8875 Supplement # 1 - Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT (I )Immediately contact any affected owner whose name is not on the list Give the owner a copy of the Owner Letter and schedule a service date. This contact includes owners who have purchased aftermarket hitch kit # F75Z-17D826-AE. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8876 REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Supplement # 1 - Attachment II LABOR ALLOWANCES PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8877 Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown above. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information above: SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. (I )REWORK OF EXISTING DEALER STOCK Call the Recall Hotline at 1-800-325-5621,to obtain instructions for reworking existing stock of Trailer Hitch Kits (part # F75Z-17D826-AE). NOTE: The Recall Hotline will provide new hardware and kit installation instructions.When you rework dealer stock, please make sure these revised instructions (with new torque specifications) are included in the kit. DEALER PRICE For latest prices, refer to: ^ DOESII ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Supplement # 1 - Attachment III HITCH ATTACHING FASTENER REPLACEMENT AFFECTED VEHICLES: CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8878 SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8879 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch. ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8880 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8881 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8882 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 8883 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trailer Hitch: > 01-14-1 > Jul > 01 > Recalls for Trailer Hitch: > NHTSA00V073000 > Mar > 00 > Recall 00V073000: Trailer Hitch Attaching Bolts Loose Trailer Hitch: Recalls Recall 00V073000: Trailer Hitch Attaching Bolts Loose Vehicle Description: Multi-purpose vehicles. The trailer hitch assembly to the frame attaching bolts could lose the clamp load. The trailer hitch could then separate from the vehicle. Dealers will replace the trailer hitch mounting bolts and nut plates. Owner notification began May 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1997 FORD TRUCK EXPEDITION 1997 LINCOLN TRUCK NAVIGATOR 1998 FORD TRUCK EXPEDITION 1998 LINCOLN TRUCK NAVIGATOR 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR 2000 FORD TRUCK EXPEDITION 2000 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for the obvious signs of electrical damage. VISUAL INSPECTION CHART ^ Battery Junction Box(BJB) Fuse: 5 (20A) - 20 (10A) - 19 (10A) - 101 (30A) - 108 (30A) ^ Central Junction Box (CJB) Fuse 23 (10A) ^ CJB Fuse 13 (10A) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Bulb(s) 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8892 Trailer Lamps: Symptom Related Diagnostic Procedures NOTE: Refer to the Vehicle/Diagrams for connector numbers stated in the pinpoint test. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8893 Trailer Lamps: Pinpoint Tests Connector Circuit Reference Refer to the Vehicle/Diagrams for schematic and connector information. X1 - X2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8894 Y1 - Y2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8895 Y3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8896 Z1 - Z2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8897 Z3 Tests AA: The Trailer Lamps Are Inoperative - Trailer Parking Lamps Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8898 AA1 - AA2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8899 AA3 - AA4 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8900 AA5 Tests AB: Trailer Lamps Are Inoperative - Trailer Reversing Lamps Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8901 AB1 - AB2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8902 AB3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8903 AB4 - AB5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8904 AC1 - AC2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8905 AC3 - AC4 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8906 AD1 - AD2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8907 AD3 - AD5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8908 AE1 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8909 73III Automotive Meter Or Equivalent Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Page 8910 73III Automotive Meter Or Equivalent Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8915 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8916 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8917 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8918 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8919 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8920 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8921 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8922 Trailer Connector: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8923 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8924 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8925 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8926 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8927 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8928 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8929 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8930 Trailer Connector: Electrical Diagrams Diagram 95-1 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8931 Diagram 95-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8932 Diagram 95-3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Locations Trip Computer: Locations Overhead Trip Computer Module In front of overhead console. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Locations > Page 8936 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Locations > Page 8937 Trip Computer: Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Driver/Vehicle Information Display; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Bracket > System Information > Service and Repair Front Bumper Bracket: Service and Repair BUMPER BRACKET - FRONT, EXPEDITION Removal 1. Remove the front bumper. 2. Remove the bumper bracket. 1 Remove the three bumper bolts. 2 Remove the bumper bracket. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair > Bumper Arms - Expedition Rear Bumper Reinforcement: Service and Repair Bumper Arms - Expedition BUMPER ARMS - EXPEDITION Removal 1. Remove the front bumper. 2. Remove the front bumper arms. 1 Remove the bumper arm bolts. 2 Remove the bumper arms. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair > Bumper Arms - Expedition > Page 8949 Rear Bumper Reinforcement: Service and Repair Bumper Isolator BUMPER ISOLATOR Special Service Tool(s) Special Service Tool(s) Removal and Installation 1. Remove the bumper cover. 2. Remove the rivets and the bumper isolator. 3. NOTE: Use the special tool to install the new rivets. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair REMOVAL NOTE: The windshield wiper pivot arms must be in the highest position to remove them. 1. Turn the ignition switch to the on position. 2. Turn the windshield wiper on. 3. Stop the windshield wiper pivot arms at the highest position by turning the ignition switch off. 4. Remove the windshield wiper pivot arm. 1 Remove the pivot arm nut cover. 2 Remove the nut. 3 Remove the windshield wiper pivot arm. 5. Raise and support the hood. 6. Remove the cowl grille seal. NOTE: The two cowl grilles overlap at the center. The LH cowl grille must be removed first. 7. Remove the LH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the LH cowl grille. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Service and Repair > Page 8953 8. Remove the RH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the RH cowl grille. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Adjust the pivot arms. For additional information, refer to Wiper Blade and Pivot Arm Adjustment-Windshield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL - GRILLE Removal and Installation 1. Remove the windshield wiper pivot arms (17526). 1 Remove the two covers. 2 Remove the two nuts. 3 Remove the windshield wiper pivot arms. 2. Raise and support the hood (16612). 3. Remove the cowl grille seal. 4. NOTE: The two cowl grilles overlap at the center. The LH cowl grille must be removed first. Remove the LH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the LH cowl grille. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 8958 5. Remove the RH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the RH cowl grille. 6. NOTE: Adjust the windshield wiper arms. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the front door watershield. 3. Remove the door handle. 1 Disconnect the electrical connector. 2 Remove the nuts. 3 Disconnect the front door latch to lock cylinder rod. 4 Disconnect the front door latch to outside front door handle rod at the handle and at the latch. 5 Remove the door handle by pushing it out from the bottom surface of the handle. NOTE: The front door window glass must be completely raised. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the door handle and lock cylinder rods are not preloading the latch. They should be clipped in a relaxed state with no slack. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Hinge Adjustment - Front Door, Fore and Aft Front Door Hinge: Adjustments Hinge Adjustment - Front Door, Fore and Aft HINGE ADJUSTMENT - FRONT DOOR, FORE AND AFT NOTE: Check the rear door hinge adjustment before adjusting the front door hinge. 1. Remove the front fender. 2. Loosen the front door hinge to body bolts. 3. Adjust the front door alignment to specification 4. Tighten the front door hinge to body bolts. 5. Install the front fender. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Hinge Adjustment - Front Door, Fore and Aft > Page 8970 Front Door Hinge: Adjustments Hinge Adjustment - Front Door, Horizontal and Vertical HINGE ADJUSTMENT - FRONT DOOR, HORIZONTAL AND VERTICAL 1. Loosen the front door hinge to front door bolts. 2. Adjust the front door alignment. 3. Tighten the front door hinge to front door bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications Front Door Latch: Specifications Front Door Latch Screws 10-14 Nm Front Door Latch Remote Control Screw 7.5-10.5 Nm Rear Door Latch Screws 10-14 Nm Rear Door Latch Remote Control Screw 7.5-10.5 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications > Page 8974 Front Door Latch: Service and Repair Heavy Duty Riveter SPECIAL SERVICE TOOL(S) REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. NOTE: The door glass must be completely raised. 2. Remove the front door trim panel; 3 Disconnect the interior door handle actuating rod. 1 Open the clip. 2 Disconnect the rod. 4. Position the front door watershield aside. 5. Remove the glass run channel bolt. ^ Position the glass run channel aside. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications > Page 8975 6. Remove the power door lock actuator rivet. 7. Disconnect the power door lock actuator electrical connector. ^ Release the wiring harness locator. 8. Disconnect the actuating rods. 1 Disconnect the lock cylinder actuating rod. 2 Open the locking clip. 3 Disconnect the exterior door handle actuating rod. 9. Remove the door latch bolts ^ Discard the bolts. 10. Disconnect the door ajar switch electrical connector. 11. Remove the front door latch. INSTALLATION 1. To install, reverse the removal procedure. ^ Transfer parts as necessary. ^ If necessary, use Multi-Purpose Grease F5AZ-19G209-AA (aerosol) or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. ^ Use the special tool to install the new rivets. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Specifications > Page 8976 Heavy Duty Riveter Or Equivalent Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 TRIM PANEL - FRONT DOOR, EXPEDITION Removal 1. Disconnect the battery ground cable. 2. NOTE: Release the top portion first. Remove the sail panel. 3. Remove the window regulator switch plate (14524). 4. Disconnect the electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 8980 5. Remove the top door trim panel screw. 6. Remove the door trim panel screw at the window regulator switch plate opening. 7. Remove the door trim panel screw in the courtesy lamp housing. 1 Remove the courtesy lamp lens. 2 Remove the screw. 8. Remove the inside door handle trim cover. 9. Remove the inside door handle. - Remove the bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Page 8981 10. CAUTION: To avoid damage to the front door trim panel, do not pull directly outward. Lift upward and then outward to remove the front door trim panel (23943). 11. Remove the courtesy lamp. - Turn the courtesy lamp bulb socket one-quarter of a turn and remove. 12. Disconnect the power mirror electrical connector. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the front door radio speaker. 3. Remove the front door watershield. 4. Lower the window glass to access the two window glass to regulator nuts. 5. Remove the inside glass weatherstrip. 6. Remove the front door rear glass channel bolt and position the channel aside. 7. Remove the window glass to regulator nuts. 8. Remove the front door window glass. NOTE: Slide the glass through the outboard side of the door. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair > Page 8985 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service Precautions Front Door Window Motor: Service Precautions CAUTION: Support the window glass to avoid damage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service Precautions > Page 8989 Front Door Window Motor: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOL(S) REMOVAL NOTE: The window regulator and motor are removed as an assembly. 1. Remove the front door trim panel. 2. Remove the front door radio speaker. 3. Remove the front door watershield. 4. Raise and support the front door window glass to the full up position. CAUTION: Support the window glass to avoid damage. 5. Disconnect the power window motor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service Precautions > Page 8990 6. Remove the window glass to regulator nuts. 7. Remove the motor and window regulator assembly. 1 Drill out the rivets. 2 Remove the motor and window regulator assembly. 8. Remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. NOTE: Prior to motor removal, make sure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service Precautions > Page 8991 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. ^ Cycle the door glass to make sure of gear engagement. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service Precautions > Page 8992 Heavy Duty Riveter Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Specifications Front Door Window Regulator: Specifications Window Glass To Regulator Nuts 10-14 Nm Window Regulator Nuts 10-14 Nm Quarter Window Regulator Bracket Bolt 2 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Specifications > Page 8996 Front Door Window Regulator: Service Precautions CAUTION: Support the window glass to avoid damage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Specifications > Page 8997 Front Door Window Regulator: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOL(S) REMOVAL NOTE: The window regulator and motor are removed as an assembly. 1. Remove the front door trim panel. 2. Remove the front door radio speaker. 3. Remove the front door watershield. 4. Raise and support the front door window glass to the full up position. CAUTION: Support the window glass to avoid damage. 5. Disconnect the power window motor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Specifications > Page 8998 6. Remove the window glass to regulator nuts. 7. Remove the motor and window regulator assembly. 1 Drill out the rivets. 2 Remove the motor and window regulator assembly. 8. Remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. NOTE: Prior to motor removal, make sure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Specifications > Page 8999 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. ^ Cycle the door glass to make sure of gear engagement. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Specifications > Page 9000 Heavy Duty Riveter Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 HANDLE - OUTSIDE, REAR DOOR REMOVAL 1. Remove the rear door trim panel. 2. Remove the rear door watershield. 3. Remove the outside rear door handle. 1 Remove the nuts. 2 Disconnect the rear door latch to outside rear door handle rod. 3 Remove the outside rear door handle by pushing it out from the bottom surface of the handle. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the door handle and the rear door handle rod is in a relaxed position and that the rear door handle rod is all the way up before closing the clips. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Adjustments Rear Door Hinge: Adjustments HINGE ADJUSTMENT - DOOR, REAR 1. Loosen the rear door hinge to rear door bolts. 2. Adjust the rear door alignment. 3. Tighten the rear door hinge to rear door bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Specifications Rear Door Latch: Specifications Front Door Latch Screws 10-14 Nm Front Door Latch Remote Control Screw 7.5-10.5 Nm Rear Door Latch Screws 10-14 Nm Rear Door Latch Remote Control Screw 7.5-10.5 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Specifications > Page 9012 Rear Door Latch: Service and Repair Heavy Duty Riveter SPECIAL SERVICE TOOL(S) REMOVAL NOTE: The rear door window glass must be completely raised. 1. Remove rear door trim panel. 2. Remove the rear door latch remote control. 1 Disconnect the rear door latch rod. 2 Remove the rear door latch remote control screw. 3 Slide the rear door latch remote control forward and remove. 3. Remove the rear door speaker. 1 Remove the screws. 2 Disconnect the electrical connector. 3 Remove the rear door speaker. 4. Remove the rear door watershield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Specifications > Page 9013 5. Remove the outside rear door handle. 1 Remove the nuts. 2 Disconnect the rear door latch to outside rear door handle rod. 3 Remove the outside rear door handle by pushing it out from the bottom surface of the handle. 6. Remove the child safety lock finish panel. 7. If equipped, disconnect the power door lock actuator electrical connector. 8. If equipped, drill out the power door lock actuator rivet. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Specifications > Page 9014 9. Drill out the push button rod rivet. 10. Remove the rear door latch. 1 Disconnect the door open warning lamp electrical connector. 2 Remove and discard the screws. 3 Remove the rear door latch through the outside rear door handle opening. ^ Remove any remaining actuating rods. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Specifications > Page 9015 1. To install, reverse the removal procedure. ^ If necessary, use Multi-Purpose Grease F5AZ-19G209-AA (aerosol) or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. ^ Use the Heavy Duty Riveter to install the new rivets. NOTE: ^ Make sure the latch release rod is not preloading the latch. It should be clipped in a relaxed state with no slack. ^ Install the rear door latch screw in the small opening first, followed by the large opening. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Specifications > Page 9016 Heavy Duty Riveter Or Equivalent Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 TRIM PANEL - REAR DOOR, EXPEDITION Removal 1. Remove the window regulator switch plate (14524). 2. Disconnect the electrical connector. 3. Remove the rear door handle trim cover. 4. Remove the rear inside door handle. - Remove the door handle bolt. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 9020 5. Remove the rear door trim panel screws. 6. CAUTION: To avoid damage to the rear door trim panel, do not pull directly outward. Lift upward and then outward to remove the rear door trim panel (27406). Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair REMOVAL 1. Remove the rear door trim panel. 2. Remove the rear door radio speaker. 3. Remove the rear door watershield. 4. Remove the inside glass weatherstrip. 5. Remove the rear door glass channel lower bolt. 6. Remove the rear door fixed vent screw. 7. Lift the rear door rear glass and channel away from the door glass. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Page 9024 8. Remove the window glass to regulator nuts. 9. Remove the rear door glass. NOTE: Slide the glass through the outboard side of the door. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service Precautions Rear Door Window Motor: Service Precautions CAUTION: Support the window glass to avoid damage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service Precautions > Page 9028 Rear Door Window Motor: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOL(S) REMOVAL NOTE: The window regulator and motor are removed as an assembly. 1. Remove the rear door trim panel. 2. Remove the rear door radio speaker. 3. Remove the rear door watershield. 4. Raise and support the rear door window glass to the full up position. CAUTION: Support the window glass to avoid damage. 5. Disconnect the power window motor electrical connector. 6. Remove the window glass to regulator nuts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service Precautions > Page 9029 7. Remove the motor and window regulator assembly. 1 Drill out the rivets. 2 Remove the motor and window regulator assembly. 8. Remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. NOTE: Prior to motor removal, make sure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. ^ Cycle the door glass to make sure of gear engagement. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service Precautions > Page 9030 Heavy Duty Riveter Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications Rear Door Window Regulator: Specifications Window Glass To Regulator Nuts 10-14 Nm Window Regulator Nuts 10-14 Nm Quarter Window Regulator Bracket Bolt 2 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications > Page 9034 Rear Door Window Regulator: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOL(S) REMOVAL NOTE: The window regulator and motor are removed as an assembly. 1. Remove the rear door trim panel. 2. Remove the rear door radio speaker. 3. Remove the rear door watershield. 4. Raise and support the rear door window glass to the full up position. CAUTION: Support the window glass to avoid damage. 5. Disconnect the power window motor electrical connector. 6. Remove the window glass to regulator nuts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications > Page 9035 7. Remove the motor and window regulator assembly. 1 Drill out the rivets. 2 Remove the motor and window regulator assembly. 8. Remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. NOTE: Prior to motor removal, make sure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. ^ Cycle the door glass to make sure of gear engagement. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications > Page 9036 Heavy Duty Riveter Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Locations > Page 9041 Hood Latch: Service and Repair REMOVAL NOTE: Expedition shown, Navigator similar. 1. Raise and support the hood. 2. Remove the hood latch. 1 Remove the bolts. 2 Disconnect the hood latch cable from the hood latch. 3 Remove the hood latch. INSTALLATION NOTE: Expedition shown, Navigator similar. 1. Install the hood latch. 1 Position the hood latch. 2 Connect the hood latch cable to the hood latch. 3 Finger-tighten the bolts. 2. Close the hood. NOTE: The radiator grille may need to be removed to tighten the hood latch bolts. 3. Align the hood flush with the fenders and tighten the hood latch bolts. ^ If necessary, use Multi-Purpose Grease F5AZ-19G209-AA (aerosol) or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair REMOVAL 1. Disconnect the rear window defrost grid electrical connector. 2. Remove the liftgate trim panels. 3. Disconnect the liftgate window glass support. 1 Remove the E-clip. 2 Remove the pin. 3 Disconnect the support. NOTE: Have an assistant hold the liftgate window glass. 4. Remove the liftgate window glass. 1 Remove the four bolts (two each side). 2 Remove the liftgate window glass. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 9049 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Adjustments Trunk / Liftgate Hinge: Adjustments HINGE ADJUSTMENT - LIFTGATE 1. Loosen the liftgate hinge to liftgate bolts. 2. Adjust the liftgate alignment. 3. Tighten the liftgate hinge to liftgate bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Specifications Trunk / Liftgate Handle: Specifications Liftgate Handle Nuts 7.5-10.5 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Specifications > Page 9056 Trunk / Liftgate Handle: Service Precautions CAUTION: Use care when removing the liftgate handle to avoid breaking the plastic tangs. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Specifications > Page 9057 Trunk / Liftgate Handle: Service and Repair REMOVAL 1. Remove the liftgate trim panel. 2. Remove the liftgate latch remote control bolts and position aside. 3. Remove the liftgate handle. 1 Remove the two nuts. 2 Remove the reinforcement plate. 3 Remove the liftgate handle. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Specifications > Page 9058 NOTE: ^ Make sure the handle shaft and the driver on the liftgate latch controller are properly aligned. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair Trunk / Liftgate Interior Trim Panel: Service and Repair TRIM PANEL - LIFTGATE Removal 1. Remove the upper liftgate trim panel. 2. Remove the liftgate assist strap. 1 Remove the screws. 2 Remove the liftgate assist strap. 3. Remove the lower liftgate trim panel. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Specifications Trunk / Liftgate Latch: Specifications Liftgate Latch Remote Control Bolts 10-14 Nm Liftgate Latch Screws 10-14 Nm Liftgate Window Glass Latch Screws 10-14 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Specifications > Page 9065 Trunk / Liftgate Latch: Service Precautions CAUTION: ^ Be careful not to kink the liftgate window glass control cable while disconnecting it. ^ Be careful not to kink the liftgate latch control cable while disconnecting it. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Trunk / Liftgate Latch: Service and Repair Liftgate REMOVAL 1. Disconnect the battery ground cable. 2. Remove the liftgate trim panel. 3. Separate the liftgate latch from the liftgate. 1 Remove the screws. 2 Separate the liftgate latch from the liftgate. 4. Disconnect the door open warning lamp electrical connector. 5. Disconnect the liftgate latch control cable. ^ Remove the liftgate latch. CAUTION: Be careful not to Kink the liftgate latch control cable while disconnecting it. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate > Page 9068 1. To install, reverse the removal procedure. ^ If necessary, use Multi-Purpose Grease F5AZ-19G209-AA (aerosol) or equivalent meeting Ford Specification ESR-M1C159-A to lubricate the latch. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate > Page 9069 Trunk / Liftgate Latch: Service and Repair Liftgate Latch Remote Control REMOVAL NOTE: Expedition shown, Navigator similar. 1. Remove the liftgate trim panel. 2. Remove the liftgate latch remote control bolts and position aside. 3. Disconnect the liftgate window glass latch cable. CAUTION: Be careful not to kink the liftgate window glass control cable while disconnecting it. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate > Page 9070 4. Disconnect the power door lock actuator rod. 5. Disconnect the lock cylinder rod. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate > Page 9071 6. Disconnect the liftgate latch cable. CAUTION: Be careful not to kink the liftgate latch control cable while disconnecting it. 7. Remove the liftgate latch remote control. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate > Page 9072 1. To install, reverse the removal procedure. NOTE: Expedition shown, Navigator similar. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate > Page 9073 Trunk / Liftgate Latch: Service and Repair Liftgate Window Glass REMOVAL 1. Remove the liftgate trim panel. 2. Open the liftgate window glass. 3. Disconnect the liftgate window glass control cable. CAUTION: Be careful not to kink the liftgate window glass control cable while disconnecting it. 4. Remove the back window latch. 1 Disconnect the electrical connector. 2 Remove the four screws. 3 Remove the back window latch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate > Page 9074 1. To install, reverse the removal procedure. ^ If necessary, use Multi-Purpose Grease F5AZ-19G209-AA (aerosol) or equivalent meeting Ford Specification ESR-M1C159-A to lubricate the latch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9079 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9080 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9081 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9082 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9083 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Page 9084 Trunk / Liftgate Lock Cylinder: Service and Repair REMOVAL NOTE: Individual lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current code of the vehicle. 1. Remove the liftgate trim panel. 2. Disconnect the lock cylinder rod. 3. Remove the lock cylinder. 1 Remove the retaining clip. 2 Remove the lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL - GRILLE Removal and Installation 1. Remove the windshield wiper pivot arms (17526). 1 Remove the two covers. 2 Remove the two nuts. 3 Remove the windshield wiper pivot arms. 2. Raise and support the hood (16612). 3. Remove the cowl grille seal. 4. NOTE: The two cowl grilles overlap at the center. The LH cowl grille must be removed first. Remove the LH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the LH cowl grille. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Page 9089 5. Remove the RH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the RH cowl grille. 6. NOTE: Adjust the windshield wiper arms. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > System Information > Service and Repair Front Fender: Service and Repair FENDER - FRONT, EXPEDITION Removal and Installation 1. Remove the radiator grille opening panel reinforcement (8A284). 2. If equipped, remove the front wheel opening moulding. 1 Remove the pin-type retainer. 2 Remove the screws. 3 Remove the wheel opening moulding. 3. Remove the front fender splash shield (16103). 1 Remove the screws. 2 Remove the pin-type retainers. 3 Remove the front fender splash shield. 4. Remove the cowl grille. 5. Remove the inner fender stuffer. 6. Remove the stone guard. 1 Remove the pin-type retainers. 2 Remove the stone guard. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > System Information > Service and Repair > Page 9094 7. Remove the front fender. - Remove the bolts. 8. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 Frame Components Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 9099 Radiator Support Mount Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 9100 No.1 Compression Mount Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 9101 No.2 Compression Mount Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 9102 No.3 Compression Mount Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 9103 No.5 Compression Mount The frame (5005) is made of two steel channel side rails, as well as a front crossmember and a rear crossmember, which are welded to the two side rails. Additional support structures are bolted to the side rails. The side rails and crossmembers are not replaced separately. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement Technical Service Bulletin # 00S05 Date: 000501 Recall - Trailer Hitch Hardware Replacement 00S05 SAFETY RECALL All 1997-2000 Model Year Expedition and Navigator with Trailer Hitch Package - Hitch Attachment ^ Original - May, 2000 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Notification Letter ^ Supplement # 1 - May, 2000 Aftermarket Hitch Kits and Existing Dealer Stock Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9112 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9113 Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instruction on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Attachment II Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9114 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts wilt not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information shown. SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III AFFECTED VEHICLES: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9115 CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9116 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9117 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9118 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9119 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9120 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9121 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9122 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9123 Supplement # 1 - Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT (I )Immediately contact any affected owner whose name is not on the list Give the owner a copy of the Owner Letter and schedule a service date. This contact includes owners who have purchased aftermarket hitch kit # F75Z-17D826-AE. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9124 REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Supplement # 1 - Attachment II LABOR ALLOWANCES PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9125 Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown above. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information above: SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. (I )REWORK OF EXISTING DEALER STOCK Call the Recall Hotline at 1-800-325-5621,to obtain instructions for reworking existing stock of Trailer Hitch Kits (part # F75Z-17D826-AE). NOTE: The Recall Hotline will provide new hardware and kit installation instructions.When you rework dealer stock, please make sure these revised instructions (with new torque specifications) are included in the kit. DEALER PRICE For latest prices, refer to: ^ DOESII ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Supplement # 1 - Attachment III HITCH ATTACHING FASTENER REPLACEMENT AFFECTED VEHICLES: CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9126 SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9127 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch. ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9128 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9129 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9130 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9131 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > Recalls for Trailer Hitch: > NHTSA00V073000 > Mar > 00 > Recall 00V073000: Trailer Hitch Attaching Bolts Loose Trailer Hitch: Recalls Recall 00V073000: Trailer Hitch Attaching Bolts Loose Vehicle Description: Multi-purpose vehicles. The trailer hitch assembly to the frame attaching bolts could lose the clamp load. The trailer hitch could then separate from the vehicle. Dealers will replace the trailer hitch mounting bolts and nut plates. Owner notification began May 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1997 FORD TRUCK EXPEDITION 1997 LINCOLN TRUCK NAVIGATOR 1998 FORD TRUCK EXPEDITION 1998 LINCOLN TRUCK NAVIGATOR 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR 2000 FORD TRUCK EXPEDITION 2000 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement Technical Service Bulletin # 00S05 Date: 000501 Recall - Trailer Hitch Hardware Replacement 00S05 SAFETY RECALL All 1997-2000 Model Year Expedition and Navigator with Trailer Hitch Package - Hitch Attachment ^ Original - May, 2000 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Notification Letter ^ Supplement # 1 - May, 2000 Aftermarket Hitch Kits and Existing Dealer Stock Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9141 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9142 Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instruction on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Attachment II Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9143 LABOR ALLOWANCES PARTS REQUIREMENTS Parts Ordering Information Parts wilt not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information shown. SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. DEALER PRICE For latest prices, refer to: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III AFFECTED VEHICLES: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9144 CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9145 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9146 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9147 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9148 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9149 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9150 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9151 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9152 Supplement # 1 - Attachment I OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT (I )Immediately contact any affected owner whose name is not on the list Give the owner a copy of the Owner Letter and schedule a service date. This contact includes owners who have purchased aftermarket hitch kit # F75Z-17D826-AE. NOTE: Navigator owners should receive the" Lincoln Commitment Special Handling Procedure". Before calling Lincoln owners, review Attachment IV to familiarize yourself with this special handling procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9153 REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Only Navigator owners are eligible for rental cars under the provisions of the "Lincoln Commitment Special Handling Procedure" (refer to Attachment IV). Supplement # 1 - Attachment II LABOR ALLOWANCES PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9154 Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts requirement through normal order processing channels as shown above. MATERIAL ALLOWANCE A material allowance of $5.25 per vehicle is being given to purchase an underbody coating (Super Seal or equivalent product). Claim this allowance by entering the information above: SPECIAL ORDER INFORMATION DOR/COR number 50161 identifies parts ordered for this campaign through the Recall Hotline (800-325-5621), for the first 30 days. (I )REWORK OF EXISTING DEALER STOCK Call the Recall Hotline at 1-800-325-5621,to obtain instructions for reworking existing stock of Trailer Hitch Kits (part # F75Z-17D826-AE). NOTE: The Recall Hotline will provide new hardware and kit installation instructions.When you rework dealer stock, please make sure these revised instructions (with new torque specifications) are included in the kit. DEALER PRICE For latest prices, refer to: ^ DOESII ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Supplement # 1 - Attachment III HITCH ATTACHING FASTENER REPLACEMENT AFFECTED VEHICLES: CERTAIN 1997 THROUGH 2000 MODEL YEAR EXPEDITION AND NAVIGATOR EQUIPPED WITH FACTORY INSTALLED TRAILER HITCH OVERVIEW This procedure outlines hitch assembly removal, cleaning and reinstallation using updated attaching hardware. NOTE: REMOVING THE FRAME WAX AS OUTLINED IN STEP 5 IS CRITICAL TO THE OVERALL ROBUSTNESS OF THIS REPAIR. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9155 SERVICE PROCEDURE 1. Turn off the air suspension switch, then raise and support the vehicle on a hoist. 2. Remove the hitch electrical connector bracket from the hitch assembly. 3. Position two (2) jack stands to support the hitch assembly. 4. Remove all bolts and nut plates attaching the hitch to the frame, then remove the hitch assembly from the vehicle. See Figures 1 and 2. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9156 5. Using Brake Metal Parts Cleaner (F6AZ-2C410-AB) or equivalent obtained locally, remove the frame wax from all areas where there is hitch- or nut plate-to-frame contact. This includes: ^ the inside areas of the hitch. ^ the inside and outside areas of the frame web. ^ the upper and lower areas of the frame flanges. CAUTION To avoid cross threading the bolts into the nut plates, start each bolt by hand and be sure it is threading properly into the nut plate. CAUTION Do not final tighten any bolts until all have been installed. Be sure to tighten the horizontal bolts first (Step 7) before tightening the vertical bolts (Step 8). 6. Reposition the hitch on the jack stands and install the new bolts and new nut plates. Only tighten the bolts snug at this time. 7. Tighten the horizontal attaching bolts to 175 Nm (129 lb-ft). 8. Tighten the vertical attaching bolts to 175 Nm (129 lb-ft). 9. Remove the jack stands. 10. Install the hitch electrical connector bracket. For 7-pin connectors, tighten the bolt to 48 Nm (35 lb-ft). For 4-pin connectors, tighten the bolt to 63 Nm (46 lb-ft). 11. Apply a coat of commercially available underbody anti-corrosion compound meeting Ford specification ESR-M7C54-A to the hitch attachment area ensuring adequate coverage. 12. Lower the vehicle and turn on the air suspension switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9157 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9158 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9159 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > 00S05 > May > 00 > Recall - Trailer Hitch Hardware Replacement > Page 9160 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trailer Hitch: > NHTSA00V073000 > Mar > 00 > Recall 00V073000: Trailer Hitch Attaching Bolts Loose Trailer Hitch: All Technical Service Bulletins Recall 00V073000: Trailer Hitch Attaching Bolts Loose Vehicle Description: Multi-purpose vehicles. The trailer hitch assembly to the frame attaching bolts could lose the clamp load. The trailer hitch could then separate from the vehicle. Dealers will replace the trailer hitch mounting bolts and nut plates. Owner notification began May 15, 2000. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1997 FORD TRUCK EXPEDITION 1997 LINCOLN TRUCK NAVIGATOR 1998 FORD TRUCK EXPEDITION 1998 LINCOLN TRUCK NAVIGATOR 1999 FORD TRUCK EXPEDITION 1999 LINCOLN TRUCK NAVIGATOR 2000 FORD TRUCK EXPEDITION 2000 LINCOLN TRUCK NAVIGATOR Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair Grille: Service and Repair RADIATOR GRILLE - EXPEDITION Removal 1. Raise and support the hood (16612). 2. Remove the jack handle. 3. Remove the front upper air deflector (19E525). 1 Remove the pin type retainers. 2 Remove the front upper air deflector. 4. Remove the headlamps (13008). 5. Remove the combination marker lamp. 6. Remove the eight stone guard pin-type retainers. 7. Remove the 10 radiator grille screws. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Page 9168 8. Remove the radiator grille (8200). - Release the clips from the radiator grille opening panel reinforcement. Installation 1. NOTE: Install the screws in the sequence indicated. To install, reverse the removal procedure. Use the locating notch to position the radiator grille on the radiator grille opening panel reinforcement. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications Console: Specifications Front Floor Console Front Bolts 10.2-13.8 Nm Front Floor Console Rear Bolts 12 Nm Rear Floor Console Screws 10.2-13.8 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications > Page 9173 Console: Description and Operation Console - Floor, Front The front floor console consists of the following components: ^ digital audio compact disc player ^ compact disc player mounting bracket ^ compact disc player compartment trim panel ^ cellular telephone ^ radio and A/C integral control assembly ^ A/C register (upper) ^ blower assembly ^ center console finish panel ^ console finish panel mat ^ auxiliary A/C controls Console - Floor, Rear The rear console consists of the following components: ^ armrest ^ cupholders ^ storage bin Console - Overhead There are two versions of the overhead console. The high series overhead console contains the following: ^ message center with compass/outside air temperature and trip computer ^ moonroof switch ^ quarter flip window switches ^ map lamps ^ map lamp switches The low series overhead console contains the following: ^ message center with compass/outside air temperature ^ moonroof switch ^ map lamps ^ map lamp switches Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Console: Service and Repair Front REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. If equipped, remove the console finish panel mat. 3. If equipped, remove the console finish panel front screw. 4. Remove the console finish panel rear screw. 5. Remove the console finish panel. ^ If equipped, disconnect the parking aid switch electrical connector. ^ If equipped, disconnect the navigation display unit electrical connectors. ^ If equipped, disconnect the auxiliary A/C control electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front > Page 9176 6. Remove the front floor console front bolts. 7. Disconnect the front floor console electrical connector. ^ If equipped, disconnect the cellular phone electrical connector. 8. Remove the two front floor console rear bolt covers. 9. Remove the two front floor console rear bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front > Page 9177 10. Remove the floor console. ^ Lift the front of the floor console and slide rearward to disengage the floor brackets. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front > Page 9178 Console: Service and Repair Rear REMOVAL 1. Tilt the rear seats forward. 2. Remove the cupholder. NOTE: Pull upward on the center of the cupholder to release the pin-type retainers. 3. Remove the rear floor console front screws. 4. Remove the two rear floor console rear screws. 5. Remove the rear floor console. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front > Page 9179 INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Supplemental Restraint System ( SRS ) Depowering and Repowering Depowering Procedure Warning: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Warning: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F22 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. Warning: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 6. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 1. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse F22 (10A) to the CJB and close the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 4. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9185 The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Deactivation and Reactivation Supplemental Restraint System ( SRS ) Deactivation and Reactivation Special Tool(s) Deactivation Warning: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Warning: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. Warning: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Warning: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. Warning: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All Vehicles 1. Move and tilt the front seats to their highest and most forward position. 2. Turn all vehicle accessories OFF. 3. Turn the ignition switch to OFF. 4. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F22 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 5. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 6. Turn the ignition OFF. Warning: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9186 The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 7. Disconnect the battery ground cable (14301) and wait at least one minute. 8. Remove the two steering wheel back cover plugs. 9. Remove the two driver air bag module retaining bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9187 10. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Disconnect the horn switch electrical connector. 3. Remove the driver air bag module. 11. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9188 12. Remove the instrument panel relay cover. 13. Disconnect the passenger air bag module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9189 14. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicle without side airbags Caution: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. 15. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM) If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with side airbags 16. Disconnect the passenger seat side air bag electrical connector. 1. Slide and disengage the passenger seat side air bag electrical connector locking clip. 2. Push in to release the tab and disconnect the passenger seat side air bag electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9190 17. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 18. Disconnect the driver seat side air bag electrical connector. 1. Slide and disengage the driver seat side air bag electrical connector locking clip. 2. Push in to release the tab and disconnect the driver seat side air bag electrical connector. 19. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All Vehicles 20. Install the RCM fuse F22 (10A) to the CJB. 21. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9191 Reactivation All Vehicles 1. Remove the RCM fuse F22 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles with side airbags 3. Remove the restraint system diagnostic tool from the driver side seat air bag floor electrical connector. 4. Connect the driver seat side air bag electrical connector. 1. Connect the driver seat side air bag electrical connector. 2. Slide and engage the driver seat side air bag electrical connector locking clip. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9192 5. Remove the restraint system diagnostic tool from the passenger side seat air bag floor electrical connector. 6. Connect the passenger side seat air bag electrical connector. 1. Connect the passenger side seat air bag electrical connector. 2. Slide and engage the passenger side seat air bag electrical connector locking clip. All Vehicles 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9193 8. Connect the passenger air bag module electrical connector. 9. Install the instrument panel relay cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9194 10. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Connect and position the driver air bag module. 1. Connect the horn switch electrical connector. 2. Connect the driver air bag module electrical connector. 3. Position the driver air bag module to the steering wheel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9195 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 14. 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. 15. Turn the ignition switch from OFF to ON. 16. Install the RCM fuse F22 (10A) to the CJB and close the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 17. Connect the battery ground cable. 18. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 9196 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Is the air bag system connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Are the side air bag electrical connectors beneath the front seats connected? 4. Is the Restraints Control Module (RCM) connected? 5. Is the vehicle battery connected? Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair Glove Compartment: Service and Repair Glove Box Spring Tool SPECIAL SERVICE TOOL(S) REMOVAL 1. Open the glove compartment. 2. Lower the glove compartment. 1 Move the glove compartment stops to align with the opening. 2 Lower the glove compartment. 3. Install the Glove Box Spring Tool. 1 Hold the glove compartment open. 2 Install the Glove Box Spring Tool. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Page 9200 4. Remove the glove compartment. 1 Remove the bolts. 2 Remove the glove compartment. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Page 9201 Glove Box Spring Tool Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures Headliner: Procedures Safety Belt Bolt Bit SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the safety belt guide nuts. 1 Lift the four covers. 2 Remove the four nuts. 2. Remove the two C-pillar trim panels. NOTE: Remove the upper attachments first, followed by the front lower attachment and the lower rear hook. 3. Remove the LH and RH A-pillar assist handles. 1 Remove the four screw covers and four screws. 2 Remove the two A-pillar assist handles. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 9206 4. Remove the two windshield side garnish mouldings. ^ If equipped, on the LH windshield side garnish moulding, disconnect the cellular phone hands-free microphone electrical connector. NOTE: Release the top attachments by pulling inboard first and then upward to release the lower hook. 5. Remove the coat hooks. 1 Open the access cover. 2 Insert a screwdriver into the slot and rotate. 3 Remove the coat hooks. 6. Remove the two front door scuff plates. 7. Remove the two rear door scuff plates. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 9207 8. Remove the two B-pillar assist handles. 1 Remove the four covers (two on each handle). 2 Remove the four screws (two on each handle). 3 Remove the two B-pillar assist handles. 9. Position the two B-pillar trim panels aside. ^ Remove the two front and two rear door weather seals. NOTE: Remove the upper attachments first and then the lower attachments. 10. Position the two sun visors into the side window position and remove the two inside screws. 11. Position the two sun visors into the stored position. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 9208 12. Remove the two sun visors and visor arm clips. 1 Remove the four screws. 2 Remove the two sun visors and visor arm clips. ^ If equipped, disconnect the sun visor electrical connectors. 13. Remove the rear courtesy lamps. 14. If equipped, remove the second row seat dome lamp assembly. 1 Remove the lens cover. 2 Remove the screws. 3 Remove the second row seat dome lamp assembly. 15. Remove the rear header garnish trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 9209 16. If equipped, remove the two third row safety belt guides. 1 Lift the two covers. 2 Use Safety Belt Bolt Bit to remove the safety belt guide bolts. 3 Remove the two third row safety belt guides. 17. Remove the two D-pillar trim panels. ^ Remove the liftgate door opening weather seal. NOTE: Remove the lower hook attached to the quarter trim panel, followed by the top attachment, and then the lower rear attachment. 18. If equipped, remove the full overhead console (without roof opening panel). 1 Remove the screw from the inside of the sunglass storage bin. 2 Release the three clips and slide the roof console forward and then down. 3 Disconnect the electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 9210 19. If equipped, remove the mini overhead console (with roof opening panel). 1 Release the four mounting clips by pulling the roof console straight down. 2 Disconnect the electrical connectors. 20. If equipped, remove the rear auxiliary climate control head assembly. 1 Slide the assembly forward and then downward. 2 Disconnect the electrical connectors. 21. If equipped, remove the roof opening panel motor access cover. 22. If equipped, remove the roof opening panel trim from the headliner. 23. Remove the headliner. ^ Remove the retainers. NOTE: If equipped, remove the auxiliary A/C duct on the LH C-pillar. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 9211 Headliner: Removal and Replacement HEADLINER Special Service Tool(s) Special Service Tool(s) Removal and Installation 1. Remove the safety belt guide nuts. 1 Lift the four covers. 2 Remove the four nuts. 2. NOTE: Remove the upper attachments first, followed by the front lower attachment and the lower rear hook. Remove the two C-pillar trim panels. 3. Remove the LH and RH A-pillar assist handles. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 9212 1 Remove the four screw covers and four screws. 2 Remove the two A-pillar assist handles. 4. NOTE: Release the top attachments by pulling inboard first and then upward to release the lower hook. Remove the two windshield side garnish mouldings. If equipped, on the LH windshield side garnish moulding, disconnect the cellular phone hands-free microphone electrical connector. 5. Remove the coat hooks. 1 Open the access cover. 2 Insert a screwdriver into the slot and rotate. 3 Remove the coat hooks. 6. Remove the two front door scuff plates (13208). 7. Remove the two rear door scuff plates (13228). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 9213 8. Remove the two B-pillar assist handles. 1 Remove the four covers (two on each handle). 2 Remove the four screws (two on each handle). 3 Remove the two B-pillar assist handles. 9. NOTE: Remove the upper attachments first and then the lower attachments. Position the two B-pillar trim panels aside. Remove the two front and two rear door weather seals. 10. Position the two sun visors into the side window position and remove the two inside screws. 11. Position the two sun visors into the stored position. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 9214 12. Remove the two sun visors and visor arm clips. 1 Remove the four screws. 2 Remove the two sun visors and visor arm clips. If equipped, disconnect the sun visor electrical connectors. 13. Remove the rear courtesy lamps. 14. If equipped, remove the second row seat dome lamp assembly. 1 Remove the lens cover. 2 Remove the screws. 3 Remove the second row seat dome lamp assembly. 15. Remove the rear header garnish trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 9215 16. If equipped, remove the two third row safety belt guides. 1 Lift the two covers. 2 Use Safety Belt Bolt Bit to remove the safety belt guide bolts. 3 Remove the two third row safety belt guides. 17. NOTE: Remove the lower hook attached to the quarter trim panel, followed by the top attachment, and then the lower rear attachment. Remove the two D-pillar trim panels. Remove the liftgate door opening weather seal. 18. If equipped, remove the full overhead console (without roof opening panel). 1 Remove the screw from the inside of the sunglass storage bin. 2 Release the three clips and slide the roof console forward and then down. 3 Disconnect the electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 9216 19. If equipped, remove the mini overhead console (with roof opening panel). 1 Release the four mounting clips by pulling the roof console straight down. 2 Disconnect the electrical connectors. 20. If equipped, remove the rear auxiliary climate control head assembly. 1 Slide the assembly forward and then downward. 2 Disconnect the electrical connectors. 21. If equipped, remove the roof opening panel motor access cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 9217 22. If equipped, remove the roof opening panel trim from the headliner. 23. NOTE: If equipped, remove the auxiliary A/C duct on the LH C-pillar. Remove the headliner. Remove the retainers. 24. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures Trim Panel: Procedures Liftgate Trim Panel REMOVAL 1. Remove the upper liftgate trim panel. 2. Remove the liftgate assist strap. 1 Remove the screws. 2 Remove the liftgate assist strap. 3. Remove the lower liftgate trim panel. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9222 1. To install, reverse the removal procedure. Quarter Trim Panel Safety Belt Bolt Bit SPECIAL SERVICE TOOL(S) REMOVAL 1. Remove the liftgate door opening weather seal. 2. Remove the liftgate scuff plate. 3. If equipped, remove the third row seat. 4. Remove the rear header garnish trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9223 5. Remove the rear door scuff plates. 6. Fold down the second row seat. 7. Remove the cross car scuff plate. 8. Remove the second row safety belt guide nut. 1 Lift the cover. 2 Remove the nut. 9. Remove the second row safety belt lower nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9224 10. Remove the C-pillar trim panel. ^ Remove the rear door opening weather seal. ^ Remove the C-pillar trim panel. NOTE: Remove the upper attachments followed by the lower attachment and the lower rear hook. 11. If equipped, remove the third row safety belt guide. 1 Lift the cover. 2 Use Safety Belt Bolt Bit to remove the safety belt guide bolt. 3 Remove the third row safety belt guide. 12. Remove the D-pillar trim panel. ^ Remove the liftgate door opening weather seal. NOTE: Remove the lower hook attached to the quarter trim panel, followed by the top attachment, and then the lower rear attachment. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9225 13. Remove the quarter trim panel. 1 Remove the screws and pin-type retainer. 2 Remove the quarter trim panel. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9226 Trim Panel: Removal and Replacement TRIM PANEL - QUARTER Special Service Tool(s) Special Service Too(s) Removal 1. Remove the liftgate door opening weather seal. 2. Remove the liftgate scuff plate. 3. If equipped, remove the third row seat. 4. Remove the rear header garnish trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9227 5. Remove the rear door scuff plates (13228). 6. Fold down the second row seat. 7. Remove the cross car scuff plate. 8. Remove the second row safety belt guide nut. 1 Lift the cover. 2 Remove the nut. 9. Remove the second row safety belt lower nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9228 10. NOTE: Remove the upper attachments followed by the lower attachment and the lower rear hook. Remove the C-pillar trim panel. Remove the rear door opening weather seal. - Remove the C-pillar trim panel. 11. If equipped, remove the third row safety belt guide. 1 Lift the cover. 2 Use Safety Belt Bolt Bit to remove the safety belt guide bolt. 3 Remove the third row safety belt guide. 12. NOTE: Remove the lower hook attached to the quarter trim panel, followed by the top attachment, and then the lower rear attachment. Remove the D-pillar trim panel. Remove the liftgate door opening weather seal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 9229 13. Remove the quarter trim panel. 1 Remove the screws and pin-type retainer. 2 Remove the quarter trim panel. Installation 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Door Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9236 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9237 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9238 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9239 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9240 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Page 9241 Door Lock Cylinder: Service and Repair REMOVAL NOTE: Individual lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current code of the vehicle. 1. Remove the front door outside handle. For additional information, refer to Handle-Outside, Front Door. 2. Remove the front door lock cylinder. 1 Remove the retainer. 2 Remove the front door lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics TSB 06-15-8 08/07/06 KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005 Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006 Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006 F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan 1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to properly diagnose the concern with the keyless entry keypad, it is important to identify whether the keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF) style keypad. ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic service tips. SERVICE PROCEDURE IDENTIFICATION: 1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and are wired directly to the module controlling the vehicle's keyless entry system. This style keypad can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9247 2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13 mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM (Figure 1). NOTE THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD DIAGNOSTICS FOR THESE VEHICLES. GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS 1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed using a similar procedure. Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter programming portion of the WSM, Section 501-14 can be used as a guide NOTE THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN ADDITIONAL REMOTE TRANSMITTER. Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the lock / unlock functions will differ 2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced separately. 3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super Duty vehicles produced prior to 12/3/2003). 4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM etc.) is replaced. NOTE THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE. 5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all doors). The keypad contains an optical sensor and will not illuminate under bright lighting conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the battery power available to transmit a lock/unlock signal. The temperature at which this occurs will vary depending upon the keypad battery age and condition. Both of these conditions are a normal function of the Power Save Mode and do not indicate a need to replace the keypad. 6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication that battery power is very low and the keypad must be replaced. 7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35 consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash during this time. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9248 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9249 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9250 Keyless Entry Key-Pad: Service and Repair REMOVAL 1. Remove the driver door trim panel. 2. Remove the keyless entry keypad. 1 Remove the screw. 2 Remove the speed ruts. 3 Remove the keyless entry keypad. ^ Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Testing and Inspection Keyless Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Keyless Entry; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Testing and Inspection > Page 9254 Keyless Entry Module: Service and Repair RAP/General Module REMOVAL AND INSTALLATION For additional information, refer to Multifunction Electronic Control Modules (General Module). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Power Door Lock Actuator: Service and Repair Front REMOVAL 1. Remove the front door latch. For additional information, refer to Front Door Latch. 2. Remove the power door lock actuator. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front > Page 9260 Power Door Lock Actuator: Service and Repair Rear Heavy Duty Riveter SPECIAL SERVICE TOOL(S) REMOVAL 1. Disconnect the battery ground cable. NOTE: The rear door window glass must be completely raised. 2. Remove the rear door trim panel. 3. Remove the rear door watershield. 4. Disconnect the power door lock actuator electrical connector. 5. Drill out the power door lock actuator rivet. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front > Page 9261 6. Remove and discard the screws. 7. Remove the power door lock actuator. ^ Disconnect the power door lock actuator rod. INSTALLATION 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivet. NOTE: ^ Use new screws when installing the rear door latch. ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front > Page 9262 Power Door Lock Actuator: Service and Repair Liftgate Heavy Duty Riveter SPECIAL SERVICE TOOL(S) REMOVAL NOTE: Expedition shown, Navigator similar. 1. Remove the liftgate trim panel. 2. Disconnect the power door lock actuator electrical connector. 3. Drill out the rivet. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front > Page 9263 4. Disconnect the power door lock actuator rod and remove the actuator. INSTALLATION 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Page 9264 Heavy Duty Riveter Or Equivalent Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component Information > Testing and Inspection Power Door Lock Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Keyless Entry; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations Power Door Lock Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 9271 Located in the Lock Relay Block, which is located behind the right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 9272 Power Door Lock Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Right Front Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Right Front > Page 9277 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front Power Door Lock Switch: Testing and Inspection Left Front Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 9280 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 9281 Power Door Lock Switch: Testing and Inspection Right Front Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 9282 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9287 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9288 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9289 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9290 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9291 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Page 9292 Trunk / Liftgate Lock Cylinder: Service and Repair REMOVAL NOTE: Individual lock cylinders are repaired by discarding the inoperative lock cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current code of the vehicle. 1. Remove the liftgate trim panel. 2. Disconnect the lock cylinder rod. 3. Remove the lock cylinder. 1 Remove the retaining clip. 2 Remove the lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions Heated Element: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9298 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9299 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9300 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9301 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9302 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9303 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9304 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9305 Heated Element: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9306 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9307 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9308 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9309 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9310 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9311 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 9312 Diagram 56-1 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Testing and Inspection Power Mirror Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Mirrors; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page 9323 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Exterior Rear View Mirror Switch Power Mirror Switch: Testing and Inspection Exterior Rear View Mirror Switch Component Testing Procedure (Part 1 Of 2) Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Exterior Rear View Mirror Switch > Page 9326 Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Exterior Rear View Mirror Switch > Page 9327 Power Mirror Switch: Testing and Inspection Power Folding Mirror Switch Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Exterior Rear View Mirror Switch > Page 9328 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes Paint: Application and ID Paint Codes The Vehicle Certification (VC) label contains the manufacturer name, the month and year of manufacture, the certification statement, and the VIN. It also includes Gross Vehicle Weight Ratings (GVWR). Paint Codes The first set of letters/numbers listed indicate the vehicle primary body color. The second set of letters/numbers listed (if applicable) indicate a two-tone or accent body color. All colors are base coat/clear coat. ^ B2 - Harvest Gold - Expedition ^ ST - Estate Green - Expedition ^ LL - Deep Wedgewood Blue - Expedition ^ LD - Medium Wedgewood Blue - Expedition ^ FS - Spruce Green - Navigator ^ SU - Amazon Green - Expedition ^ BQ - Light Parchment Gold - Navigator ^ E9 - Laser Red Tint - Expedition/Navigator ^ JL - Dark Toreador Red - Expedition ^ UA - Ebony - Expedition/Navigator ^ YZ - Oxford White - Expedition/Navigator ^ YN - Silver Metallic - Expedition ^ KW - Charcoal Blue - Navigator ^ FT - Charcoal Green - Navigator ^ Y1 - Prime Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9334 Interior Trim Codes The following lists the interior trim and interior color codes. Interior Trim ^ M - Manitou cloth split bench seat ^ F - Manitou cloth captains chairs (XLT) ^ S - Vinyl captains chairs (XLT) ^ l - Leather captains chairs (Eddie Bauer, XLT) ^ K - Super-soft leather captains chairs (Navigator) ^ 7 - Woven cloth captains chairs (XLT Sport) Interior Color Codes ^ H - Medium Parchment ^ 2 - Medium Graphite ^ T - Dark Graphite Tape Stripe Codes Tape and paint stripe codes do not apply. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9335 Paint: Application and ID Paint Code Sticker Location VEHICLE CERTIFICATION LABEL REFERENCE The VC label is located on the left-hand front door or door jamb and is in a similar location on trucks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9336 Paint: Application and ID Vehicle Identification Codes IDENTIFICATION CODES The Vehicle Identification Number (VIN) is a seventeen-digit combination of letters and numbers. The VIN is stamped on a metal tab riveted on the instrument panel, top upper left of the dash. The VIN number is also found on the Vehicle Certification (VC) label. Vehicle Identification Number The first three vehicle identification number (VIN) positions are the world manufacturer identifier. 1FM - Ford Motor Company, USA, multi-purpose vehicle - 5LM - Lincoln, USA, multi-purpose vehicle Positions 5 through 7 indicate vehicle line, series and body type. U15 - Expedition, 4x2, XLT - U16 - Expedition, 4x4, XLT - U17 - Expedition, 4x2, Eddie Bauer - U18 - Expedition, 4x4, Eddie Bauer - U27 - Navigator, 4x2 - U28 - Navigator, 4x4 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9337 Paint: Application and ID Vehicle Certification Labels The Vehicle Certification (VC) label contains the manufacturer name, the month and year of manufacture, the certification statement, and the VIN. It also includes Gross Vehicle Weight Ratings (GVWR). Paint Codes The first set of letters/numbers listed indicate the vehicle primary body color. The second set of letters/numbers listed (if applicable) indicate a two-tone or accent body color. All colors are base coat/clear coat. ^ B2 - Harvest Gold - Expedition ^ ST - Estate Green - Expedition ^ LL - Deep Wedgewood Blue - Expedition ^ LD - Medium Wedgewood Blue - Expedition ^ FS - Spruce Green - Navigator ^ SU - Amazon Green - Expedition ^ BQ - Light Parchment Gold - Navigator ^ E9 - Laser Red Tint - Expedition/Navigator ^ JL - Dark Toreador Red - Expedition ^ UA - Ebony - Expedition/Navigator ^ YZ - Oxford White - Expedition/Navigator ^ YN - Silver Metallic - Expedition ^ KW - Charcoal Blue - Navigator ^ FT - Charcoal Green - Navigator ^ Y1 - Prime Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9338 Interior Trim Codes The following lists the interior trim and interior color codes. Interior Trim ^ M - Manitou cloth split bench seat ^ F - Manitou cloth captains chairs (XLT) ^ S - Vinyl captains chairs (XLT) ^ l - Leather captains chairs (Eddie Bauer, XLT) ^ K - Super-soft leather captains chairs (Navigator) ^ 7 - Woven cloth captains chairs (XLT Sport) Interior Color Codes ^ H - Medium Parchment ^ 2 - Medium Graphite ^ T - Dark Graphite Tape Stripe Codes Tape and paint stripe codes do not apply. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Testing and Inspection Keyless Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Keyless Entry; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Testing and Inspection > Page 9343 Keyless Entry Module: Service and Repair RAP/General Module REMOVAL AND INSTALLATION For additional information, refer to Multifunction Electronic Control Modules (General Module). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module > Component Information > Testing and Inspection Power Door Lock Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Keyless Entry; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Power Door Lock Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 9350 Located in the Lock Relay Block, which is located behind the right side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 9351 Power Door Lock Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Testing and Inspection Power Mirror Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Mirrors; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Heated Seat Module Power Seat Control Module: Locations Heated Seat Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Heated Seat Module > Page 9359 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Heated Seat Module > Page 9360 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Heated Seat Module Power Seat Control Module: Diagrams Heated Seat Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Heated Seat Module > Page 9363 Power Seat Control Module: Diagrams Driver Memory Seat Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Heated Seat Module > Page 9364 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Heated Seat Module > Page 9365 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Page 9366 Power Seat Control Module: Service Precautions WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Diagrams > Page 9367 Power Seat Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Seats; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service and Repair > Seat Module Power Seat Control Module: Service and Repair Seat Module REMOVAL WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. ^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in. side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. ^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. If equipped with side air bags, deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the power seat track. For additional information, refer to Seat Track-Power, with Side Air Bag or Seat Track-Power, without Side Air Bag. 3. Remove the seat module. NOTE: For additional information regarding this component please refer to Multifunction Electronic Control Modules. INSTALLATION 1. To install, reverse the removal procedure. 2. If equipped with side air bags, reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 3. If equipped, prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Service and Repair > Seat Module > Page 9370 Power Seat Control Module: Service and Repair Heated REMOVAL WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. ^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. ^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. If equipped with side air bags, deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the power seat track. For additional information, refer to Seat Track-Power, with Side Air Bag or Seat Track-Power, without Side Air Bag. 3. Disconnect the electrical connectors. 4. Remove the heated seat module. ^ Release the clip. INSTALLATION 1. To install, reverse the removal procedure. 2. If equipped with side air bags, reactivate the supplemental restraint system For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 3. If equipped, prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Passenger Temperature Controlled Seat Module Seat Heater Control Module: Locations Passenger Temperature Controlled Seat Module Under passenger seat. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Passenger Temperature Controlled Seat Module > Page 9375 Seat Heater Control Module: Locations Driver Temperature Controlled Seat Module Under driver seat. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Driver Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Driver > Page 9378 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service Precautions > Technician Safety Information Seat Heater Control Module: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service Precautions > Technician Safety Information > Page 9381 Seat Heater Control Module: Vehicle Damage Warnings WARNING: ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service Precautions > Page 9382 Seat Heater Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Seats; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Service and Repair Sunroof / Moonroof Module: Service and Repair REMOVAL 1. Close the roof opening panel. 2. Disconnect the battery ground cable. For additional information, refer to Battery. 3. Remove the headliner. 4. Slide the roof opening panel module from the retaining bracket. 5. Disconnect the electrical connectors and remove the roof opening panel module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Specifications Sunroof / Moonroof Motor: Specifications Roof Opening Panel Motor Bolts 5 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Specifications > Page 9391 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Specifications > Page 9392 Sunroof / Moonroof Motor: Service and Repair REMOVAL 1. Remove the headliner. 2. Remove the three roof opening panel motor bolts. 3. Disconnect the electrical connector and remove the roof opening panel motor. INSTALLATION NOTE: The roof opening panel module must be installed prior to motor installation. For additional information, refer to Module-Roof Opening Panel. 1. Connect the electrical connector. NOTE: The roof opening panel should be in the closed position. 2. Cycle the roof opening panel motor until it stops in the closed position. 3. Remove the roof opening panel. For additional information, refer to Sunroof/Moonroof. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Specifications > Page 9393 4. Insert two 1/8 inch diameter pins through both portions of the roof opening panel lifter assemblies. 5. Install the roof opening panel motor. ^ Install the three bolts. NOTE: It may be necessary to rotate the roof opening panel motor slightly to engage the drive splines. 6. Remove the pins. 7. Install the roof opening panel. For additional information, refer to Sunroof/Moonroof. 8. Install the headliner. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > Customer Interest: > 03-11-10 > Jun > 03 > Body - Moonroof Water Leaks/Won't Open Properly Sunroof / Moonroof Track: Customer Interest Body - Moonroof Water Leaks/Won't Open Properly Article No. 03-11-10 06/09/03 ^ BODY - WATER LEAK FROM ROOF OPENING PANEL - ROOF OPENING PANEL BINDS OR WILL NOT OPEN PROPERLY ^ NOISE - RATTLE FROM ROOF OPENING PANEL AREA FORD: 2000-2003 EXPEDITION 2001-2003 F-150 2003 SUPER DUTY F SERIES LINCOLN: 2000-2003 NAVIGATOR ISSUE Some 2000-2003 Expedition/Navigator, 2001-2003 F-Series Under 8500, and 2003 F-Series over 8500 vehicles may exhibit a rattle from the root opening panel (moonroof) area, a failure of the roof opening panel to open properly, or a water leak from the roof opening panel. This may be due to the water trough being separated from the trough guide on either side, as a result of a broken trough guide. ACTION Check if the water trough is securely attached to the trough guide at each end. Check for damage to the lifter arm assemblies at the joint where the trough guide metal rods attach. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF ROOF OPENING PANEL SERVICE IS PERFORMED BY A SUBLET FACILITY, MAKE SURE THIS ARTICLE IS REFERENCED DURING SERVICE. The trough guide is a small plastic piece with a metal rod attachment which is responsible for guiding the roof opening panel water trough along the roof opening panel track as the panel opens and closes. The roof opening panel water trough is a metal tray that attaches to the trough guides at each end and is responsible for collecting water as the glass panel tilts and operates. In cases where a water trough becomes loose, it will rattle against the rearward portion of the roof opening panel assembly during driving. Likewise, it may result in the roof opening glass opening without the interior shade opening simultaneously. It may also prevent the glass panel from fully opening or closing. A separated water trough may lead to a water leak into the vehicle at the rear of the roof opening glass when the moonroof is opened. Check if the water trough is securely attached to the trough guide at each end. Check for damage to the lifter arm assemblies at the joint where the trough guide metal rods attach. Before replacing the guides and trough, inspect the roof opening panel track for broken plastic guide pieces, and remove them. Be sure to discard the original water trough and use a new trough, even if damage to the trough itself is not apparent. The new water trough design has fully enclosed screw holes rather than open-ended slots for securing it to the trough guides. If there is no damage to the lifter arm assemblies, but the water trough and guide are separated on either side, replace BOTH trough guides AND the water trough (serviceable subassemblies of the roof opening panel assembly) according to the following replacement instructions. If there is damage to the lifter arm assembly or assemblies, replace the moonroof assembly according to Workshop Manual Section 501-17. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > Customer Interest: > 03-11-10 > Jun > 03 > Body - Moonroof Water Leaks/Won't Open Properly > Page 9405 Rear Trough Guide Replacement 1. Remove the root opening panel (glass). Refer to Workshop Manual Section 501-17 for removal instructions. 2. Remove the two trough guide retaining screws (Figure 1). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > Customer Interest: > 03-11-10 > Jun > 03 > Body - Moonroof Water Leaks/Won't Open Properly > Page 9406 3. Remove and discard the water trough (Figure 2). One end of the trough may still be attached to the trough guide - if so, remove it from the trough guide assembly. 4. Disconnect the trough guide wire from the moonroof lifter arm mechanism on either side (Figure 3). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > Customer Interest: > 03-11-10 > Jun > 03 > Body - Moonroof Water Leaks/Won't Open Properly > Page 9407 5. Slide the trough guide assembly through the small slot in the tracks to remove it on each side (Figure 4). 6. Inspect the trough guide assemblies for damage. If damage is found, inspect the roof opening panel track for the broken pieces and remove any pieces found. 7. Carefully twist the new trough guide through the small slot in the tracks to install it. 8. Connect the trough guide wire to the lifter arm mechanism on either side. 9. Set the NEW water trough onto the trough guide assemblies. 10. Tighten the two screws (one on each side) through the holes into the trough guide assembly holes. Torque to 1.0 +/- 0.25 N.m (9 +/- 2 lb-in). 11. Re-install the roof opening panel according to Workshop Manual section 501-17. 12. Adjust the glass flushness as specified in Workshop Manual section 501-17. NOTE WHEN PROPERLY ADJUSTED, THE TOP OF THE SEAL BULB AT THE FRONT OF THE GLASS PANEL SHOULD BE FLUSH TO 0.060" (1.5 MM) LOWER THAN THE ROOF SURFACE, AND THE TOP OF THE SEAL BULB AT THE REAR OF THE GLASS PANEL SHOULD BE FLUSH TO 0.060" (1.5 MM) HIGHER THAN THE ROOF SURFACE. 13. Cycle test the moonroof through the vent and full open positions to check for proper function. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO CODE 78500A64 01 OASIS CODES: 102000, 105000, 108000, 110000, 111000, 702000, 702100, 702300 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > Customer Interest: > 03-11-10 > Jun > 03 > Body - Moonroof Water Leaks/Won't Open Properly > Page 9408 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-11-10 > Jun > 03 > Body - Moonroof Water Leaks/Won't Open Properly Sunroof / Moonroof Track: All Technical Service Bulletins Body - Moonroof Water Leaks/Won't Open Properly Article No. 03-11-10 06/09/03 ^ BODY - WATER LEAK FROM ROOF OPENING PANEL - ROOF OPENING PANEL BINDS OR WILL NOT OPEN PROPERLY ^ NOISE - RATTLE FROM ROOF OPENING PANEL AREA FORD: 2000-2003 EXPEDITION 2001-2003 F-150 2003 SUPER DUTY F SERIES LINCOLN: 2000-2003 NAVIGATOR ISSUE Some 2000-2003 Expedition/Navigator, 2001-2003 F-Series Under 8500, and 2003 F-Series over 8500 vehicles may exhibit a rattle from the root opening panel (moonroof) area, a failure of the roof opening panel to open properly, or a water leak from the roof opening panel. This may be due to the water trough being separated from the trough guide on either side, as a result of a broken trough guide. ACTION Check if the water trough is securely attached to the trough guide at each end. Check for damage to the lifter arm assemblies at the joint where the trough guide metal rods attach. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF ROOF OPENING PANEL SERVICE IS PERFORMED BY A SUBLET FACILITY, MAKE SURE THIS ARTICLE IS REFERENCED DURING SERVICE. The trough guide is a small plastic piece with a metal rod attachment which is responsible for guiding the roof opening panel water trough along the roof opening panel track as the panel opens and closes. The roof opening panel water trough is a metal tray that attaches to the trough guides at each end and is responsible for collecting water as the glass panel tilts and operates. In cases where a water trough becomes loose, it will rattle against the rearward portion of the roof opening panel assembly during driving. Likewise, it may result in the roof opening glass opening without the interior shade opening simultaneously. It may also prevent the glass panel from fully opening or closing. A separated water trough may lead to a water leak into the vehicle at the rear of the roof opening glass when the moonroof is opened. Check if the water trough is securely attached to the trough guide at each end. Check for damage to the lifter arm assemblies at the joint where the trough guide metal rods attach. Before replacing the guides and trough, inspect the roof opening panel track for broken plastic guide pieces, and remove them. Be sure to discard the original water trough and use a new trough, even if damage to the trough itself is not apparent. The new water trough design has fully enclosed screw holes rather than open-ended slots for securing it to the trough guides. If there is no damage to the lifter arm assemblies, but the water trough and guide are separated on either side, replace BOTH trough guides AND the water trough (serviceable subassemblies of the roof opening panel assembly) according to the following replacement instructions. If there is damage to the lifter arm assembly or assemblies, replace the moonroof assembly according to Workshop Manual Section 501-17. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-11-10 > Jun > 03 > Body - Moonroof Water Leaks/Won't Open Properly > Page 9414 Rear Trough Guide Replacement 1. Remove the root opening panel (glass). Refer to Workshop Manual Section 501-17 for removal instructions. 2. Remove the two trough guide retaining screws (Figure 1). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-11-10 > Jun > 03 > Body - Moonroof Water Leaks/Won't Open Properly > Page 9415 3. Remove and discard the water trough (Figure 2). One end of the trough may still be attached to the trough guide - if so, remove it from the trough guide assembly. 4. Disconnect the trough guide wire from the moonroof lifter arm mechanism on either side (Figure 3). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-11-10 > Jun > 03 > Body - Moonroof Water Leaks/Won't Open Properly > Page 9416 5. Slide the trough guide assembly through the small slot in the tracks to remove it on each side (Figure 4). 6. Inspect the trough guide assemblies for damage. If damage is found, inspect the roof opening panel track for the broken pieces and remove any pieces found. 7. Carefully twist the new trough guide through the small slot in the tracks to install it. 8. Connect the trough guide wire to the lifter arm mechanism on either side. 9. Set the NEW water trough onto the trough guide assemblies. 10. Tighten the two screws (one on each side) through the holes into the trough guide assembly holes. Torque to 1.0 +/- 0.25 N.m (9 +/- 2 lb-in). 11. Re-install the roof opening panel according to Workshop Manual section 501-17. 12. Adjust the glass flushness as specified in Workshop Manual section 501-17. NOTE WHEN PROPERLY ADJUSTED, THE TOP OF THE SEAL BULB AT THE FRONT OF THE GLASS PANEL SHOULD BE FLUSH TO 0.060" (1.5 MM) LOWER THAN THE ROOF SURFACE, AND THE TOP OF THE SEAL BULB AT THE REAR OF THE GLASS PANEL SHOULD BE FLUSH TO 0.060" (1.5 MM) HIGHER THAN THE ROOF SURFACE. 13. Cycle test the moonroof through the vent and full open positions to check for proper function. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO CODE 78500A64 01 OASIS CODES: 102000, 105000, 108000, 110000, 111000, 702000, 702100, 702300 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-11-10 > Jun > 03 > Body - Moonroof Water Leaks/Won't Open Properly > Page 9417 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Track: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Track: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9423 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Track: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9424 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Track: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9430 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Track: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9431 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Drain: > 03-11-10 > Jun > 03 > Body - Moonroof Water Leaks/Won't Open Properly Sunroof / Moonroof Drain: Customer Interest Body - Moonroof Water Leaks/Won't Open Properly Article No. 03-11-10 06/09/03 ^ BODY - WATER LEAK FROM ROOF OPENING PANEL - ROOF OPENING PANEL BINDS OR WILL NOT OPEN PROPERLY ^ NOISE - RATTLE FROM ROOF OPENING PANEL AREA FORD: 2000-2003 EXPEDITION 2001-2003 F-150 2003 SUPER DUTY F SERIES LINCOLN: 2000-2003 NAVIGATOR ISSUE Some 2000-2003 Expedition/Navigator, 2001-2003 F-Series Under 8500, and 2003 F-Series over 8500 vehicles may exhibit a rattle from the root opening panel (moonroof) area, a failure of the roof opening panel to open properly, or a water leak from the roof opening panel. This may be due to the water trough being separated from the trough guide on either side, as a result of a broken trough guide. ACTION Check if the water trough is securely attached to the trough guide at each end. Check for damage to the lifter arm assemblies at the joint where the trough guide metal rods attach. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF ROOF OPENING PANEL SERVICE IS PERFORMED BY A SUBLET FACILITY, MAKE SURE THIS ARTICLE IS REFERENCED DURING SERVICE. The trough guide is a small plastic piece with a metal rod attachment which is responsible for guiding the roof opening panel water trough along the roof opening panel track as the panel opens and closes. The roof opening panel water trough is a metal tray that attaches to the trough guides at each end and is responsible for collecting water as the glass panel tilts and operates. In cases where a water trough becomes loose, it will rattle against the rearward portion of the roof opening panel assembly during driving. Likewise, it may result in the roof opening glass opening without the interior shade opening simultaneously. It may also prevent the glass panel from fully opening or closing. A separated water trough may lead to a water leak into the vehicle at the rear of the roof opening glass when the moonroof is opened. Check if the water trough is securely attached to the trough guide at each end. Check for damage to the lifter arm assemblies at the joint where the trough guide metal rods attach. Before replacing the guides and trough, inspect the roof opening panel track for broken plastic guide pieces, and remove them. Be sure to discard the original water trough and use a new trough, even if damage to the trough itself is not apparent. The new water trough design has fully enclosed screw holes rather than open-ended slots for securing it to the trough guides. If there is no damage to the lifter arm assemblies, but the water trough and guide are separated on either side, replace BOTH trough guides AND the water trough (serviceable subassemblies of the roof opening panel assembly) according to the following replacement instructions. If there is damage to the lifter arm assembly or assemblies, replace the moonroof assembly according to Workshop Manual Section 501-17. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Drain: > 03-11-10 > Jun > 03 > Body - Moonroof Water Leaks/Won't Open Properly > Page 9440 Rear Trough Guide Replacement 1. Remove the root opening panel (glass). Refer to Workshop Manual Section 501-17 for removal instructions. 2. Remove the two trough guide retaining screws (Figure 1). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Drain: > 03-11-10 > Jun > 03 > Body - Moonroof Water Leaks/Won't Open Properly > Page 9441 3. Remove and discard the water trough (Figure 2). One end of the trough may still be attached to the trough guide - if so, remove it from the trough guide assembly. 4. Disconnect the trough guide wire from the moonroof lifter arm mechanism on either side (Figure 3). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Drain: > 03-11-10 > Jun > 03 > Body - Moonroof Water Leaks/Won't Open Properly > Page 9442 5. Slide the trough guide assembly through the small slot in the tracks to remove it on each side (Figure 4). 6. Inspect the trough guide assemblies for damage. If damage is found, inspect the roof opening panel track for the broken pieces and remove any pieces found. 7. Carefully twist the new trough guide through the small slot in the tracks to install it. 8. Connect the trough guide wire to the lifter arm mechanism on either side. 9. Set the NEW water trough onto the trough guide assemblies. 10. Tighten the two screws (one on each side) through the holes into the trough guide assembly holes. Torque to 1.0 +/- 0.25 N.m (9 +/- 2 lb-in). 11. Re-install the roof opening panel according to Workshop Manual section 501-17. 12. Adjust the glass flushness as specified in Workshop Manual section 501-17. NOTE WHEN PROPERLY ADJUSTED, THE TOP OF THE SEAL BULB AT THE FRONT OF THE GLASS PANEL SHOULD BE FLUSH TO 0.060" (1.5 MM) LOWER THAN THE ROOF SURFACE, AND THE TOP OF THE SEAL BULB AT THE REAR OF THE GLASS PANEL SHOULD BE FLUSH TO 0.060" (1.5 MM) HIGHER THAN THE ROOF SURFACE. 13. Cycle test the moonroof through the vent and full open positions to check for proper function. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO CODE 78500A64 01 OASIS CODES: 102000, 105000, 108000, 110000, 111000, 702000, 702100, 702300 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Drain: > 03-11-10 > Jun > 03 > Body - Moonroof Water Leaks/Won't Open Properly > Page 9443 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Drain: > 03-11-10 > Jun > 03 > Body - Moonroof Water Leaks/Won't Open Properly Sunroof / Moonroof Drain: All Technical Service Bulletins Body - Moonroof Water Leaks/Won't Open Properly Article No. 03-11-10 06/09/03 ^ BODY - WATER LEAK FROM ROOF OPENING PANEL - ROOF OPENING PANEL BINDS OR WILL NOT OPEN PROPERLY ^ NOISE - RATTLE FROM ROOF OPENING PANEL AREA FORD: 2000-2003 EXPEDITION 2001-2003 F-150 2003 SUPER DUTY F SERIES LINCOLN: 2000-2003 NAVIGATOR ISSUE Some 2000-2003 Expedition/Navigator, 2001-2003 F-Series Under 8500, and 2003 F-Series over 8500 vehicles may exhibit a rattle from the root opening panel (moonroof) area, a failure of the roof opening panel to open properly, or a water leak from the roof opening panel. This may be due to the water trough being separated from the trough guide on either side, as a result of a broken trough guide. ACTION Check if the water trough is securely attached to the trough guide at each end. Check for damage to the lifter arm assemblies at the joint where the trough guide metal rods attach. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF ROOF OPENING PANEL SERVICE IS PERFORMED BY A SUBLET FACILITY, MAKE SURE THIS ARTICLE IS REFERENCED DURING SERVICE. The trough guide is a small plastic piece with a metal rod attachment which is responsible for guiding the roof opening panel water trough along the roof opening panel track as the panel opens and closes. The roof opening panel water trough is a metal tray that attaches to the trough guides at each end and is responsible for collecting water as the glass panel tilts and operates. In cases where a water trough becomes loose, it will rattle against the rearward portion of the roof opening panel assembly during driving. Likewise, it may result in the roof opening glass opening without the interior shade opening simultaneously. It may also prevent the glass panel from fully opening or closing. A separated water trough may lead to a water leak into the vehicle at the rear of the roof opening glass when the moonroof is opened. Check if the water trough is securely attached to the trough guide at each end. Check for damage to the lifter arm assemblies at the joint where the trough guide metal rods attach. Before replacing the guides and trough, inspect the roof opening panel track for broken plastic guide pieces, and remove them. Be sure to discard the original water trough and use a new trough, even if damage to the trough itself is not apparent. The new water trough design has fully enclosed screw holes rather than open-ended slots for securing it to the trough guides. If there is no damage to the lifter arm assemblies, but the water trough and guide are separated on either side, replace BOTH trough guides AND the water trough (serviceable subassemblies of the roof opening panel assembly) according to the following replacement instructions. If there is damage to the lifter arm assembly or assemblies, replace the moonroof assembly according to Workshop Manual Section 501-17. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Drain: > 03-11-10 > Jun > 03 > Body - Moonroof Water Leaks/Won't Open Properly > Page 9449 Rear Trough Guide Replacement 1. Remove the root opening panel (glass). Refer to Workshop Manual Section 501-17 for removal instructions. 2. Remove the two trough guide retaining screws (Figure 1). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Drain: > 03-11-10 > Jun > 03 > Body - Moonroof Water Leaks/Won't Open Properly > Page 9450 3. Remove and discard the water trough (Figure 2). One end of the trough may still be attached to the trough guide - if so, remove it from the trough guide assembly. 4. Disconnect the trough guide wire from the moonroof lifter arm mechanism on either side (Figure 3). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Drain: > 03-11-10 > Jun > 03 > Body - Moonroof Water Leaks/Won't Open Properly > Page 9451 5. Slide the trough guide assembly through the small slot in the tracks to remove it on each side (Figure 4). 6. Inspect the trough guide assemblies for damage. If damage is found, inspect the roof opening panel track for the broken pieces and remove any pieces found. 7. Carefully twist the new trough guide through the small slot in the tracks to install it. 8. Connect the trough guide wire to the lifter arm mechanism on either side. 9. Set the NEW water trough onto the trough guide assemblies. 10. Tighten the two screws (one on each side) through the holes into the trough guide assembly holes. Torque to 1.0 +/- 0.25 N.m (9 +/- 2 lb-in). 11. Re-install the roof opening panel according to Workshop Manual section 501-17. 12. Adjust the glass flushness as specified in Workshop Manual section 501-17. NOTE WHEN PROPERLY ADJUSTED, THE TOP OF THE SEAL BULB AT THE FRONT OF THE GLASS PANEL SHOULD BE FLUSH TO 0.060" (1.5 MM) LOWER THAN THE ROOF SURFACE, AND THE TOP OF THE SEAL BULB AT THE REAR OF THE GLASS PANEL SHOULD BE FLUSH TO 0.060" (1.5 MM) HIGHER THAN THE ROOF SURFACE. 13. Cycle test the moonroof through the vent and full open positions to check for proper function. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage DEALER CODING CONDITION BASIC PART NO CODE 78500A64 01 OASIS CODES: 102000, 105000, 108000, 110000, 111000, 702000, 702100, 702300 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Drain: > 03-11-10 > Jun > 03 > Body - Moonroof Water Leaks/Won't Open Properly > Page 9452 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Service and Repair Sunroof / Moonroof Module: Service and Repair REMOVAL 1. Close the roof opening panel. 2. Disconnect the battery ground cable. For additional information, refer to Battery. 3. Remove the headliner. 4. Slide the roof opening panel module from the retaining bracket. 5. Disconnect the electrical connectors and remove the roof opening panel module. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Recalls for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions Technical Service Bulletin # 00L11 Date: 000201 Information O0L11 SPECIAL FIELD ACTION Certain 2000 and 2001 Model Year Expedition and Navigator and Certain 2001 Model Year F-150 Super Cab, Taurus, and Sable Vehicles - Revised Owner's Guide Child Tether Instruction Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Recalls for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 9465 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Recalls for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 9466 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $5,000 per vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Recalls for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 9467 DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Owner's Guide Page Labels or Owner's Guides Owner's Guide page labels and new Owner's Guides for this program are being sent directly to customers of the affected vehicles. Additional labels (for customers who prefer to have this label installed at the dealership and arrive without the label) or Owner's Guides (for dealer stock units) may be ordered as follows: Call 1-800-325-5621 ^ Ask for an additional Owner's Guide page label or Owner's Guide for program OOL1 1 ^ Provide vehicle model year and make to obtain the correct Owner's Guide page label or Owner's Guide DEALER PRICE Dealers will not be charged for the Owner's Guide page labels or Owner's Guides ordered under this program. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 2001 MODEL YEAR TAURUS AND SABLE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Recalls for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 9468 TAURUS OWNER'S GUIDE LABEL PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Recalls for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 9469 SABLE OWNER'S GUIDE LABEL PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Recalls for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 9470 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Recalls for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 9471 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions Technical Service Bulletin # 00L11 Date: 000201 Information O0L11 SPECIAL FIELD ACTION Certain 2000 and 2001 Model Year Expedition and Navigator and Certain 2001 Model Year F-150 Super Cab, Taurus, and Sable Vehicles - Revised Owner's Guide Child Tether Instruction Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 9477 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 9478 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $5,000 per vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 9479 DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Owner's Guide Page Labels or Owner's Guides Owner's Guide page labels and new Owner's Guides for this program are being sent directly to customers of the affected vehicles. Additional labels (for customers who prefer to have this label installed at the dealership and arrive without the label) or Owner's Guides (for dealer stock units) may be ordered as follows: Call 1-800-325-5621 ^ Ask for an additional Owner's Guide page label or Owner's Guide for program OOL1 1 ^ Provide vehicle model year and make to obtain the correct Owner's Guide page label or Owner's Guide DEALER PRICE Dealers will not be charged for the Owner's Guide page labels or Owner's Guides ordered under this program. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 2001 MODEL YEAR TAURUS AND SABLE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 9480 TAURUS OWNER'S GUIDE LABEL PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 9481 SABLE OWNER'S GUIDE LABEL PROCEDURE Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 9482 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Child Seat: > 00L11 > Feb > 00 > Recall - Revised Child Tether Instructions > Page 9483 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Locations > Heated Seat Module Power Seat Control Module: Locations Heated Seat Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Locations > Heated Seat Module > Page 9492 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Locations > Heated Seat Module > Page 9493 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Heated Seat Module Power Seat Control Module: Diagrams Heated Seat Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Heated Seat Module > Page 9496 Power Seat Control Module: Diagrams Driver Memory Seat Module Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Heated Seat Module > Page 9497 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Heated Seat Module > Page 9498 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Page 9499 Power Seat Control Module: Service Precautions WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams > Page 9500 Power Seat Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Seats; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Service and Repair > Seat Module Power Seat Control Module: Service and Repair Seat Module REMOVAL WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. ^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in. side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. ^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. If equipped with side air bags, deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the power seat track. For additional information, refer to Seat Track-Power, with Side Air Bag or Seat Track-Power, without Side Air Bag. 3. Remove the seat module. NOTE: For additional information regarding this component please refer to Multifunction Electronic Control Modules. INSTALLATION 1. To install, reverse the removal procedure. 2. If equipped with side air bags, reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 3. If equipped, prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Service and Repair > Seat Module > Page 9503 Power Seat Control Module: Service and Repair Heated REMOVAL WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. ^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. ^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. 1. If equipped with side air bags, deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the power seat track. For additional information, refer to Seat Track-Power, with Side Air Bag or Seat Track-Power, without Side Air Bag. 3. Disconnect the electrical connectors. 4. Remove the heated seat module. ^ Release the clip. INSTALLATION 1. To install, reverse the removal procedure. 2. If equipped with side air bags, reactivate the supplemental restraint system For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 3. If equipped, prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver > Page 9508 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service Precautions > Technician Safety Information Power Seat Motor: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING AN AIR BAG MODULE. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ INSPECT THE SIDE AIR BAG MODULE MOUNTING BRACKET FOR DAMAGE. IF THE MOUNTING BRACKET IS DAMAGED DO NOT ATTEMPT TO REPAIR THE SEAT BACKREST FRAME OR SIDE AIR BAG MODULE MOUNTING BRACKET. IF DAMAGED, THE SEAT BACKREST FRAME MUST BE INSTALLED NEW. FAILURE TO DO SO MAY CAUSE THE SIDE AIR BAG MODULE TO NOT FUNCTION CORRECTLY, POSSIBLY RESULTING IN PERSONAL INJURY. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service Precautions > Technician Safety Information > Page 9511 Power Seat Motor: Vehicle Damage Warnings WARNING: ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Heated Seat Switch Power Seat Switch: Diagrams Heated Seat Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Heated Seat Switch > Page 9516 Power Seat Switch: Diagrams Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Heated Seat Switch > Page 9517 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Heated Seat Switch > Page 9518 Power Seat Switch: Diagrams Power Lumbar Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information Power Seat Switch: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information > Page 9521 Power Seat Switch: Vehicle Damage Warnings WARNING: ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver Power Seat Switch: Testing and Inspection Driver Without Memory Component Testing Procedure (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9524 Component Testing Procedure (Part 2 Of 2) Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9525 Schematic With Memory Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9526 Component Testing Procedure (Part 1 Of 2) Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9527 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9528 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9529 Power Seat Switch: Testing and Inspection Passenger Without Lumbar Component Testing Procedure (Part 1 Of 2) Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9530 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9531 Schematic With Lumbar Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9532 Component Testing Procedure (Part 1 Of 2) Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9533 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9534 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch Power Seat Switch: Service and Repair Seat Control Switch Without Side Air Bags REMOVAL NOTE: Driver side shown, passenger side similar. 1. Disconnect the battery ground cable. 2. Remove the front seat back adjust handle. 1 Remove the screw. 2 Remove the front seat back adjust handle. 3. Pull to remove the front seat lumbar support handle. 4. Remove the front seat track shield screws. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 9537 5. Remove the pin-type retainer on the back of the front seat track shield. 6. Remove the screws on the bottom of the front seat track shield. 7. Disconnect the seat regulator control switch from the front of the front seat track shield. 1 Remove the screws. 2 Disconnect the seat regulator control switch. NOTE: If equipped with heated seats, disconnect the switch. 8. Disconnect the seat regulator control switch electrical connector and remove the seat regulator control switch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 9538 1. To install, reverse the removal procedure. NOTE: ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. ^ If equipped with heated seats, connect the switch. With Side Air Bags WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 9539 ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems of the appropriate car/truck service manual. ^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. ^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. ^ Navigator is shown, Expedition is similar. REMOVAL 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the seat from the vehicle. For additional information, refer to Front Seat-Captain's Chair with Side Air Bag. 3. Remove the screw and the seat latch handle. 4. Remove the screw. 5. From the front underside of the seat cushion frame, remove and disconnect the seat control and climate control switch (if equipped) electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 9540 6. Remove the screws. 7. Remove the pin-type retainer. 8. Remove the side shield. 1 Pull the side shield out far enough and disconnect the power lumbar switch. 2 Pull the wire harnesses through the seat cushion frame and remove the side shield. 9. Remove the seat control switch from the side shield. 1 Remove the screws. 2 Remove the seat control switch. INSTALLATION 1. To install, reverse the removal procedure. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 9541 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 3. If equipped, prove out the air bag system. For additional information, refer to Air Bag systems. 4. Check the restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 9542 Power Seat Switch: Service and Repair Lumbar Control Switch WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems of the appropriate car/truck service manual. ^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. ^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. REMOVAL 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the seat from the vehicle. For additional information, refer to Front Seat-Captain's Chair with Side Air Bag. 3. Remove the screw and the seat latch handle. 4. Remove the screw. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 9543 5. From the front underside of the seat cushion frame, remove and disconnect the seat control and climate control switch (if equipped) electrical connectors. 6. Remove the screws. 7. Remove the pin-type retainer. 8. Remove the side shield. 1 Pull the side shield out far enough to access the power lumbar switch and disconnect the switch. 2 Pull the wire harnesses through the seat cushion frame and remove the side shield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 9544 9. Remove the lumbar control switch from the side shield. ^ Release the tabs and remove the lumbar control switch. INSTALLATION 1. To install, reverse the removal procedure. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 3. If equipped, prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service Precautions Seat Cushion: Service Precautions WARNING ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING AN AIR BAG MODULE. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation Seat Cushion: Service and Repair Removal And Installation REMOVAL 1. Remove the seat from the vehicle. For additional information, refer to Rear Seat-Second Row, 40 Percent E-Z Entry. 2. Remove the seat-to-seat base bolts (one shown). 3. Position the base out of the way and remove the seat-to-seat base bolts and the seat cushion. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9550 Seat Cushion: Service and Repair Disassembly and Assembly Captain's Chair Without Side Air Bag DISASSEMBLY 1. Disassemble the front captain's chair. For additional information, refer to Front Seat-Captain's Chair and 40 Percent Seat, Without Side Air Bags. 2. Unfasten the front seat cushion cover J-clips. 3. Remove the six hog rings and remove the front seat cushion trim cover. 4. Remove the front seat cushion pad pin-type retainers. 5. Remove the front seat cushion pad from the front seat cushion frame. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9551 6. If equipped, and if necessary, remove the seat cushion heating element. CAUTION: Any time the seat cushion heating element is removed from the seat cushion foam, the foam must be replaced. ASSEMBLY 1. If equipped, connect the seat cushion heating element to the leading edge of the seat cushion. 1 Install commercially available double-sided tape. 2 Connect the element to the tape. 2. If equipped, position the seat cushion heating element into the recess of the seat cushion foam. 3. If equipped, connect the seat cushion heating element to the center area of the seat cushion. 1 Install the commercially available double-sided tape. 2 Connect the element to the tape. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9552 4. If equipped, position the seat cushion heating element into the recess of the seat cushion foam. 5. If equipped, connect the seat cushion heating element to the rear area of the seat cushion. 1 Install the commercially available double-sided tape. 2 Connect the element to the tape. 6. Insert the front seat cushion pad into the front seat cushion frame. ^ If equipped, position the seat cushion heating element electrical lead. 7. Install the front seat cushion pad pin-type retainers. 8. Position the front seat cushion cover and install the listing wires and hog rings. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9553 9. Fasten the seat cushion cover J-clips. 10. Check the restraint system for correct operation. 60% Bench DISASSEMBLY 1. Disassemble the 60% front seat. For additional information, refer to Seat-Front, 60% Bench. 2. Unfasten the front seat cushion cover retainers. 3. Remove the five front seat cushion trim cover hog rings and remove the 60% front seat cushion trim cover. 4. Separate the front seat cushion frame from the front seat cushion foam. ASSEMBLY 1. To assemble, reverse the disassembly procedure. 2. Check the restraint system for correct operation. Second Row, 60% Portion of 60/40 Split Bench Safety Belt Bolt Bit SPECIAL SERVICE TOOL(S) DISASSEMBLY 1. Disassemble the 60% portion of the second row 60/40 split bench. For additional information, refer to Seat-Second Row, 60% Portion of 60/40 Split Bench. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9554 2. Remove the safety belt divider. 3. Disconnect the seat trim cover J-clips. 4. Remove the safety belt retractor. 1 Using the special tool, remove the bolt. 2 Remove the safety belt retractor. 5. Remove the seat cushion frame from the seat cushion foam and trim cover. 6. Remove the seat cushion trim cover from the seat cushion foam. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9555 7. Remove the seat riser. 1 Remove the two bolts. 2 Remove the seat riser. ASSEMBLY 1. Install the seat risers. 1 Position the risers. 2 Install the two bolts. NOTE: Make sure the bushings are installed. 2. Install the seat cushion trim cover to the seat cushion foam. 3. Insert the seat cushion frame into the seat cushion foam and trim cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9556 4. Install the safety belt retractor. ^ Using the special tool, install the bolt. 5. Install the seat cover. ^ Connect the seat cover J-clips. ^ Install the hog rings and listing wires. ^ Connect the hook and loop fastener. 6. Install the safety belt buckle divider. 7. Check the restraint system for correct operation. Third Row Safety Belt Bolt Bit SPECIAL SERVICE TOOL(S) DISASSEMBLY Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9557 1. Disassemble the third row seat. For additional information, refer to Seat-Third Row. 2. Remove the tether anchor. 1 Remove the bolt. 2 Remove the tether anchor. 3. Remove the seat cushion trim cover and foam from the seat cushion frame. ^ Unhook the J-clips. 4. Remove the seat cushion trim cover from the seat cushion foam. 5. Remove the safety belts. ^ Using special tool 501-010 (T77L-2100-A), remove the two bolts. 6. Remove the seat riser. ^ Remove the nuts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9558 7. Remove the four seat rollers. 1 Remove the four bolts. 2 Remove the four wheels. ASSEMBLY 1. To assemble, reverse the disassembly procedure. 2. Check the restraint system for correct operation. Rear Seat Cushion DISASSEMBLY 1. Remove the rear seat cushion from the chair. For additional information, refer to Rear Seat-Second Row, 40 Percent E-Z Entry. 2. Release the hook and loop strips and open the cushion flap. 3. Remove the hog rings. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal And Installation > Page 9559 4. Release the J-clips. 5. Remove the seat cushion frame. 6. Release the hook and loop strips. CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip, or the hook and loop strip can be torn from the seat cushion foam. 7. Remove the trim cover from the seat cushion. 1 Remove the hog rings. 2 Remove the trim cover from the seat cushion. ASSEMBLY 1. To assemble, reverse the disassembly procedure. 2. Check the restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Driver Seat Heater And Temperature Sensor Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Driver Seat Heater And Temperature Sensor > Page 9564 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Seat Backrest Thermo-Electric Device Seat Heater: Diagrams Seat Backrest Thermo-Electric Device Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Seat Backrest Thermo-Electric Device > Page 9567 Seat Heater: Diagrams Seat Cushion Thermo-Electric Drive Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 9568 Seat Heater: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Seats; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Passenger Temperature Controlled Seat Module Seat Heater Control Module: Locations Passenger Temperature Controlled Seat Module Under passenger seat. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Passenger Temperature Controlled Seat Module > Page 9573 Seat Heater Control Module: Locations Driver Temperature Controlled Seat Module Under driver seat. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Driver Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Driver > Page 9576 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service Precautions > Technician Safety Information Seat Heater Control Module: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service Precautions > Technician Safety Information > Page 9579 Seat Heater Control Module: Vehicle Damage Warnings WARNING: ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service Precautions > Page 9580 Seat Heater Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Seats; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Driver Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Driver > Page 9585 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service Precautions > Technician Safety Information Seat Track: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING AN AIR BAG MODULE. ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service Precautions > Technician Safety Information > Page 9590 Seat Track: Vehicle Damage Warnings CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle can result in damaged components. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Manual Seat Track: Service and Repair Manual REMOVAL 1. Remove the front seat back adjust handle. 1 Remove the screw. 2 Remove the front seat back adjust handle. 2. Pull to remove the front seat lumbar support handle. 3. Remove the front seat track shield screws. 4. Remove the pin-type retainer on the back of the front seat track shield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Manual > Page 9593 5. Remove the screws on the bottom of the front seat track shield. 6. Remove the seat track to seat cushion front bolts. 1 Position the seat track rearward. 2 Remove the seat track to seat cushion front bolts. 7. Remove the seat track assembly. 1 Position the seat track forward. 2 Remove the seat track rear bolts. 3 Remove the seat track assembly. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Manual > Page 9594 1. Install the seat track. 1 Position the seat track. 2 Loosely install the seat track rear bolts. 2. Install the seat track to seat cushion front bolts. 1 Position the seat track rearward. 2 Install the seat track to seat cushion front bolts. 3. Tighten the seat track rear bolts. 4. Install the screws on the bottom of the front seat track shield. 5. Install the pin-type retainer on the back of the front seat track shield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Manual > Page 9595 6. Install the front seat track shield screws. 7. If equipped, install the lumbar support handle. 8. Install the seat back adjust handle. ^ Install the screw. 9. Check the restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Manual > Page 9596 Seat Track: Service and Repair Power Without Side Air Bag REMOVAL 1. Remove the four seat track to seat cushion bolts. 2. Disconnect the electrical connectors. 3. Remove the seat track. INSTALLATION 1. To install, reverse the removal procedure. 2. Check the restraint system for correct operation. With Side Air Bag WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTER HANDLING AN AIR BAG MODULE. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Manual > Page 9597 ^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle can result in damaged components. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems. ^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. ^ Diagnostics may be performed on seat Systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. ^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. ^ Navigator is shown, Expedition is similar. 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the seat from the vehicle. For additional information, refer to Front Seat-Captain's Chair with Side Air Bag. 3. Remove the pin-type retainers and disconnect the wire connectors. 1 Remove the side air bag wire connector from the bracket. 2 Disconnect the power lumbar connector. 3 Remove the safety belt buckle warning connector from the bracket and disconnect it. NOTE: If the pin-type retainers are damaged, install new retainers. This will keep the wire harnesses routed correctly. 4. Remove the pin-type retainers and disconnect the wire connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Manual > Page 9598 1 Remove the lower Thermo-Electric Device (TED) connector from the seat track (if equipped). 2 Remove the seat control wire harness and connector from the seat cushion frame. 3 Disconnect the small climate control module connector (if equipped). 4 Remove the seat control switch connector and disconnect it. ^ Disconnect the power lumbar connector (not shown). NOTE: If the pin-type retainers are damaged, install new retainers. This will keep the wire harnesses routed correctly. 5. Remove the bolts. 6. Remove the wire harness and the power seat track. INSTALLATION 1. To install, reverse the removal procedure. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 3. If equipped, prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Right Front Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Right Front > Page 9604 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front Power Door Lock Switch: Testing and Inspection Left Front Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 9607 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 9608 Power Door Lock Switch: Testing and Inspection Right Front Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Left Front > Page 9609 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 9613 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Exterior Rear View Mirror Switch Power Mirror Switch: Testing and Inspection Exterior Rear View Mirror Switch Component Testing Procedure (Part 1 Of 2) Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Exterior Rear View Mirror Switch > Page 9616 Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Exterior Rear View Mirror Switch > Page 9617 Power Mirror Switch: Testing and Inspection Power Folding Mirror Switch Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Exterior Rear View Mirror Switch > Page 9618 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Heated Seat Switch Power Seat Switch: Diagrams Heated Seat Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Heated Seat Switch > Page 9623 Power Seat Switch: Diagrams Power Seat Control Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Heated Seat Switch > Page 9624 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Heated Seat Switch > Page 9625 Power Seat Switch: Diagrams Power Lumbar Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information Power Seat Switch: Technician Safety Information WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service Precautions > Technician Safety Information > Page 9628 Power Seat Switch: Vehicle Damage Warnings WARNING: ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver Power Seat Switch: Testing and Inspection Driver Without Memory Component Testing Procedure (Part 1 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9631 Component Testing Procedure (Part 2 Of 2) Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9632 Schematic With Memory Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9633 Component Testing Procedure (Part 1 Of 2) Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9634 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9635 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9636 Power Seat Switch: Testing and Inspection Passenger Without Lumbar Component Testing Procedure (Part 1 Of 2) Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9637 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9638 Schematic With Lumbar Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9639 Component Testing Procedure (Part 1 Of 2) Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9640 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Testing and Inspection > Driver > Page 9641 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch Power Seat Switch: Service and Repair Seat Control Switch Without Side Air Bags REMOVAL NOTE: Driver side shown, passenger side similar. 1. Disconnect the battery ground cable. 2. Remove the front seat back adjust handle. 1 Remove the screw. 2 Remove the front seat back adjust handle. 3. Pull to remove the front seat lumbar support handle. 4. Remove the front seat track shield screws. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 9644 5. Remove the pin-type retainer on the back of the front seat track shield. 6. Remove the screws on the bottom of the front seat track shield. 7. Disconnect the seat regulator control switch from the front of the front seat track shield. 1 Remove the screws. 2 Disconnect the seat regulator control switch. NOTE: If equipped with heated seats, disconnect the switch. 8. Disconnect the seat regulator control switch electrical connector and remove the seat regulator control switch. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 9645 1. To install, reverse the removal procedure. NOTE: ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. ^ If equipped with heated seats, connect the switch. With Side Air Bags WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 9646 ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems of the appropriate car/truck service manual. ^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. ^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. ^ Navigator is shown, Expedition is similar. REMOVAL 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the seat from the vehicle. For additional information, refer to Front Seat-Captain's Chair with Side Air Bag. 3. Remove the screw and the seat latch handle. 4. Remove the screw. 5. From the front underside of the seat cushion frame, remove and disconnect the seat control and climate control switch (if equipped) electrical connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 9647 6. Remove the screws. 7. Remove the pin-type retainer. 8. Remove the side shield. 1 Pull the side shield out far enough and disconnect the power lumbar switch. 2 Pull the wire harnesses through the seat cushion frame and remove the side shield. 9. Remove the seat control switch from the side shield. 1 Remove the screws. 2 Remove the seat control switch. INSTALLATION 1. To install, reverse the removal procedure. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 9648 WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 3. If equipped, prove out the air bag system. For additional information, refer to Air Bag systems. 4. Check the restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 9649 Power Seat Switch: Service and Repair Lumbar Control Switch WARNING: ^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT. ^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE, DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES. PLEASE REFER TO THE APPROPRIATE VEHICLE SHOP MANUAL TO DETERMINE LOCATION OF THE FRONT AIR BAG SENSORS. THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR. TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER SUPPLIES (IF EQUIPPED). ^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. NOTE: ^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system must be deactivated per the deactivation procedure contained in Air Bag Systems of the appropriate car/truck service manual. ^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the side airbag to floor connector. ^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector at the floor connector. The restraint system diagnostic tool must be removed prior to operating the vehicle. ^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar, climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the restraint system diagnostic tool is installed under the seat in the side airbag to floor connector. ^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed before operating the vehicle. REMOVAL 1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. 2. Remove the seat from the vehicle. For additional information, refer to Front Seat-Captain's Chair with Side Air Bag. 3. Remove the screw and the seat latch handle. 4. Remove the screw. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 9650 5. From the front underside of the seat cushion frame, remove and disconnect the seat control and climate control switch (if equipped) electrical connectors. 6. Remove the screws. 7. Remove the pin-type retainer. 8. Remove the side shield. 1 Pull the side shield out far enough to access the power lumbar switch and disconnect the switch. 2 Pull the wire harnesses through the seat cushion frame and remove the side shield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat Control Switch > Page 9651 9. Remove the lumbar control switch from the side shield. ^ Release the tabs and remove the lumbar control switch. INSTALLATION 1. To install, reverse the removal procedure. 2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag Systems. WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS. 3. If equipped, prove out the air bag system. For additional information, refer to Air Bag Systems. 4. Check the restraint system for correct operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Driver Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Driver > Page 9656 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation Sound Proofing / Insulation: Description and Operation INSULATION Insulation is installed: - Under the roof. - Above and below the instrument panel (04304). - At the cowl sides. - Over the transmission tunnel. - Over the floorpan areas. - Inside the quarter panels. And has heat-bondable mastic deadeners for improved NVH characteristics (Navigator). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > Customer Interest for Tailgate: > 04-18-11 > Sep > 04 > Body - Corrosion At Bottom of Door or Tailgate Tailgate: Customer Interest Body - Corrosion At Bottom of Door or Tailgate TSB 04-18-11 09/20/04 BODY - CORROSION AT BOTTOM OF DOOR OR TAILGATE HEM FLANGE - REPAIR PROCEDURE FORD: 1997-2001 Taurus 2000-2001 Focus 1997-2001 Expedition, F-250 LD, Windstar, F-Series LINCOLN: 1998-2001 Navigator MERCURY: 1997-2001 Sable This article supersedes TSB 01-09-8 to update the vehicle line and model year coverage and service procedure. ISSUE Some vehicles may exhibit corrosion at the hem flange at bottom of any door/tailgate where the outer panel is folded over the inner panel. ACTION Repair corrosion at the hem flange using special hem flange tools. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE READ THIS REPAIR PROCEDURE COMPLETELY BEFORE PERFORMING ANY SERVICE ACTIONS. NOTE THE USE OF FORD OR MOTORCRAFT BRAND PRODUCTS ARE MANDATORY ON ALL REPAIR CLAIMS PAID BY FORD UNLESS OTHERWISE SPECIFIED IN EMISSIONS, SAFETY RECALLS, OWNER NOTIFICATION PROGRAMS, TSB'S OR OTHER COMPANY PUBLICATIONS. THE COST OF NON-FORD/MOTORCRAFT PRODUCTS USED FOR A WARRANTY, ESP/ESC OR AWA REPAIR WITHOUT JUSTIFYING THEIR USE (SUCH AS EMERGENCY REPAIR) IS NOT REIMBURSABLE. EXAMPLES OF FORD PRODUCTS ARE ADHESIVES, SEALERS, SOLVENTS, CLEANERS, WASHES, AND OTHER SPECIAL PRODUCTS LISTED IN THE FORD CAR CARE PRODUCTS MANUAL. NOTE TECHNICIANS SHOULD WEAR THE APPROPRIATE EYE, HAND AND HEARING PROTECTION WHILE PERFORMING THESE REPAIR PROCEDURES. ADHESIVES AND SEALERS USED IN THESE PROCEDURES SHOULD BE USED IN A WELL-VENTILATED AREA. 1. Inspect the inside of the door/tailgate at the lower edge only for corrosion/bubbling. 2. Follow the Workshop Manual procedure for the removal of the interior door panel or tailgate and tailgate moldings. 3. Use shop air to blow out the drain holes in the bottom of the door/tailgate and apply 25 mm (1") tape to the outer skin at the bottom to prevent scuffing. 4. Use a hammer and screwdriver to slightly lift the corner of the hem flange. 5. Insert TOOL 501-078/1(RT) or TOOL 501-078/2(LT) in an air impact gun (620 kPa (90 psi) air pressure is required for consistent tool operation). Using the tool lift the hem flange continuing across the bottom of the door/tailgate and stop just before the end. 6. Use an angle grinder or wire brush to remove all corrosion on the bottom of the hem flange and inner door/tailgate panel. Follow by blowing off with compressed air. 7. Using appropriate hand protection, brush on Corrosion Converter (Sem # 69508) on the corroded area. Use light coat and let flash dry 2-5 minutes. Follow by using a damp cloth to wipe off corrosion residue. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > Customer Interest for Tailgate: > 04-18-11 > Sep > 04 > Body - Corrosion At Bottom of Door or Tailgate > Page 9674 8. Sand with a DA sander using 360 grit sand paper the lower areas of the door/tailgate where paint was disturbed, keeping the repair area small. Feather edge for a paint blend as necessary. Blow off the panel with clean compressed air. Clean the panels with wax and remover. 9. Mix and brush on Ford approved epoxy or self-etching primer to all bare hem flange areas on the bottom of the door/tailgate. Bake at 140°F (60° C) panel temperature per manufacturers label instructions. 10. Install the Motorcraft TA-1 adhesive cartridge into the application gun 501-040. Squeeze out some material to purge the cartridge. Install the tip on the cartridge and squeeze out some material to make sure of even mixing of the adhesive components. 11. Apply the adhesive between the hem flange and bottom of the inner door/tailgate panel. Work time is 45 minutes at 70°F (21°C). Adhesive cure time is 8 hours. 12. Use TOOL 501-080 to re-hem (close down) the hem flange. Start in a corner, and insert the center of the tool over the area to close down and hit with a hammer. 13. Install the Motorcraft TA-2 urethane cartridge into the application gun 501-040. Squeeze out some material to purge the cartridge. Install the tip on the cartridge and squeeze out some material to make sure of even mixing of the adhesive components. 14. Apply Motorcraft TA-2 urethane seam sealer around the door/tailgate hem flange to give a finished appearance. 15. Remove any residual sealer with adhesive remover. Sealer is paintable in 10 minutes and within 24 hours. 16. Mask the door/tailgate for color application. 17. Mix and apply Ford approved basecoat color to the inside of the door/tailgate area and allow material to flash off. 18. Mix and apply Ford approved clearcoat to inside of the door/tailgate and bake at 140°F (60°C) panel temperature per following manufacturers recommended baking time. 19. Spray Dominion Sure Seal Amber anti corrosion coating (24011) to the inside of the door/tailgate at the hem location. Do not plug drain holes. 20. Demask the vehicle and, reinstall the inner door panel or tailgate moldings. SPECIAL TOOLS ^ 501-078/1 RH Hem Opening Tool (Tools are direct ship from O.T.C.) ^ 501-078/2 LH Hem Opening Tool ^ 501-080 Hem Closing Tool ^ 501-040 Adhesive Gun (Adhesive Gun not included in kits. This is a commonly used commercially available gun. Must be ordered separately from Rotunda.) PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate: > 04-18-11 > Sep > 04 > Body - Corrosion At Bottom of Door or Tailgate Tailgate: All Technical Service Bulletins Body - Corrosion At Bottom of Door or Tailgate TSB 04-18-11 09/20/04 BODY - CORROSION AT BOTTOM OF DOOR OR TAILGATE HEM FLANGE - REPAIR PROCEDURE FORD: 1997-2001 Taurus 2000-2001 Focus 1997-2001 Expedition, F-250 LD, Windstar, F-Series LINCOLN: 1998-2001 Navigator MERCURY: 1997-2001 Sable This article supersedes TSB 01-09-8 to update the vehicle line and model year coverage and service procedure. ISSUE Some vehicles may exhibit corrosion at the hem flange at bottom of any door/tailgate where the outer panel is folded over the inner panel. ACTION Repair corrosion at the hem flange using special hem flange tools. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE READ THIS REPAIR PROCEDURE COMPLETELY BEFORE PERFORMING ANY SERVICE ACTIONS. NOTE THE USE OF FORD OR MOTORCRAFT BRAND PRODUCTS ARE MANDATORY ON ALL REPAIR CLAIMS PAID BY FORD UNLESS OTHERWISE SPECIFIED IN EMISSIONS, SAFETY RECALLS, OWNER NOTIFICATION PROGRAMS, TSB'S OR OTHER COMPANY PUBLICATIONS. THE COST OF NON-FORD/MOTORCRAFT PRODUCTS USED FOR A WARRANTY, ESP/ESC OR AWA REPAIR WITHOUT JUSTIFYING THEIR USE (SUCH AS EMERGENCY REPAIR) IS NOT REIMBURSABLE. EXAMPLES OF FORD PRODUCTS ARE ADHESIVES, SEALERS, SOLVENTS, CLEANERS, WASHES, AND OTHER SPECIAL PRODUCTS LISTED IN THE FORD CAR CARE PRODUCTS MANUAL. NOTE TECHNICIANS SHOULD WEAR THE APPROPRIATE EYE, HAND AND HEARING PROTECTION WHILE PERFORMING THESE REPAIR PROCEDURES. ADHESIVES AND SEALERS USED IN THESE PROCEDURES SHOULD BE USED IN A WELL-VENTILATED AREA. 1. Inspect the inside of the door/tailgate at the lower edge only for corrosion/bubbling. 2. Follow the Workshop Manual procedure for the removal of the interior door panel or tailgate and tailgate moldings. 3. Use shop air to blow out the drain holes in the bottom of the door/tailgate and apply 25 mm (1") tape to the outer skin at the bottom to prevent scuffing. 4. Use a hammer and screwdriver to slightly lift the corner of the hem flange. 5. Insert TOOL 501-078/1(RT) or TOOL 501-078/2(LT) in an air impact gun (620 kPa (90 psi) air pressure is required for consistent tool operation). Using the tool lift the hem flange continuing across the bottom of the door/tailgate and stop just before the end. 6. Use an angle grinder or wire brush to remove all corrosion on the bottom of the hem flange and inner door/tailgate panel. Follow by blowing off with compressed air. 7. Using appropriate hand protection, brush on Corrosion Converter (Sem # 69508) on the corroded area. Use light coat and let flash dry 2-5 minutes. Follow by using a damp cloth to wipe off corrosion residue. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Tailgate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate: > 04-18-11 > Sep > 04 > Body - Corrosion At Bottom of Door or Tailgate > Page 9680 8. Sand with a DA sander using 360 grit sand paper the lower areas of the door/tailgate where paint was disturbed, keeping the repair area small. Feather edge for a paint blend as necessary. Blow off the panel with clean compressed air. Clean the panels with wax and remover. 9. Mix and brush on Ford approved epoxy or self-etching primer to all bare hem flange areas on the bottom of the door/tailgate. Bake at 140°F (60° C) panel temperature per manufacturers label instructions. 10. Install the Motorcraft TA-1 adhesive cartridge into the application gun 501-040. Squeeze out some material to purge the cartridge. Install the tip on the cartridge and squeeze out some material to make sure of even mixing of the adhesive components. 11. Apply the adhesive between the hem flange and bottom of the inner door/tailgate panel. Work time is 45 minutes at 70°F (21°C). Adhesive cure time is 8 hours. 12. Use TOOL 501-080 to re-hem (close down) the hem flange. Start in a corner, and insert the center of the tool over the area to close down and hit with a hammer. 13. Install the Motorcraft TA-2 urethane cartridge into the application gun 501-040. Squeeze out some material to purge the cartridge. Install the tip on the cartridge and squeeze out some material to make sure of even mixing of the adhesive components. 14. Apply Motorcraft TA-2 urethane seam sealer around the door/tailgate hem flange to give a finished appearance. 15. Remove any residual sealer with adhesive remover. Sealer is paintable in 10 minutes and within 24 hours. 16. Mask the door/tailgate for color application. 17. Mix and apply Ford approved basecoat color to the inside of the door/tailgate area and allow material to flash off. 18. Mix and apply Ford approved clearcoat to inside of the door/tailgate and bake at 140°F (60°C) panel temperature per following manufacturers recommended baking time. 19. Spray Dominion Sure Seal Amber anti corrosion coating (24011) to the inside of the door/tailgate at the hem location. Do not plug drain holes. 20. Demask the vehicle and, reinstall the inner door panel or tailgate moldings. SPECIAL TOOLS ^ 501-078/1 RH Hem Opening Tool (Tools are direct ship from O.T.C.) ^ 501-078/2 LH Hem Opening Tool ^ 501-080 Hem Closing Tool ^ 501-040 Adhesive Gun (Adhesive Gun not included in kits. This is a commonly used commercially available gun. Must be ordered separately from Rotunda.) PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL - GRILLE Removal and Installation 1. Remove the windshield wiper pivot arms (17526). 1 Remove the two covers. 2 Remove the two nuts. 3 Remove the windshield wiper pivot arms. 2. Raise and support the hood (16612). 3. Remove the cowl grille seal. 4. NOTE: The two cowl grilles overlap at the center. The LH cowl grille must be removed first. Remove the LH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the LH cowl grille. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 9686 5. Remove the RH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the RH cowl grille. 6. NOTE: Adjust the windshield wiper arms. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9696 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9697 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9698 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9699 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9700 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9701 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9702 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9703 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9704 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9705 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9706 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9707 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9708 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9709 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9710 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9711 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9712 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9713 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9714 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9715 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9716 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9717 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9718 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9719 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9720 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9721 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9726 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA05V017000 > Jan > 05 > Recall 05V017000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): Recalls Recall 05V017000: Cruise Control Deactivation Switch MAKE/MODELS: MODEL/BUILD YEARS: Ford/Expedition 2000 Ford/F150 2000 Ford/Supercrew 2001 Lincoln/Navigator 2000 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V017000 RECALL DATE: Jan 27, 2005 COMPONENT: Vehicle Speed Control: Cruise Control POTENTIAL NUMBER OF UNITS AFFECTED: 738490 SUMMARY: On certain sport utility vehicles and pickup trucks, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: This condition could lead to a fire. Fires have occurred while the vehicles were parked with the ignition "OFF." REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (early April 2005), Owners will be instructed to return to the dealers for installation of a new switch. Owners should contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9740 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9741 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9742 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9743 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9744 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9745 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9746 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9747 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9748 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9749 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9750 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9751 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9752 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9753 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9754 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9755 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9756 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9757 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9758 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9759 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9760 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9761 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9762 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9763 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9764 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9765 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9770 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA05V017000 > Jan > 05 > Recall 05V017000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): All Technical Service Bulletins Recall 05V017000: Cruise Control Deactivation Switch MAKE/MODELS: MODEL/BUILD YEARS: Ford/Expedition 2000 Ford/F150 2000 Ford/Supercrew 2001 Lincoln/Navigator 2000 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V017000 RECALL DATE: Jan 27, 2005 COMPONENT: Vehicle Speed Control: Cruise Control POTENTIAL NUMBER OF UNITS AFFECTED: 738490 SUMMARY: On certain sport utility vehicles and pickup trucks, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: This condition could lead to a fire. Fires have occurred while the vehicles were parked with the ignition "OFF." REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (early April 2005), Owners will be instructed to return to the dealers for installation of a new switch. Owners should contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 9779 Brake Switch (Cruise Control): Specifications Deactivator Switch 18 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information Brake Switch (Cruise Control): Technician Safety Information WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information > Page 9782 Brake Switch (Cruise Control): Vehicle Damage Warnings 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. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 9783 Brake Switch (Cruise Control): Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 9784 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the deactivator switch electrical connector. 3. Remove the deactivator switch. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. INSTALLATION 1. To install, reverse the removal procedure. NOTE: After the deactivator switch is installed, it is necessary to bleed the brake system; refer to Brakes. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications Cruise Control Servo: Specifications Speed Control Servo Bracket Bolts 9 Nm Speed Control Servo Bracket Screws 12 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 9791 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 9792 Cruise Control Servo: Service and Repair REMOVAL 1. Remove the speed control actuator cable cap from the speed control servo. 1 Push in the locking arm on the speed control actuator cable cap. 2 Rotate the speed control actuator cable cap counterclockwise and remove the speed control actuator cable cap from the speed control servo. 2. Disconnect the speed control actuator cable from the speed control servo. 1 Depress the spring retainer. 2 Slide the core wire end out of the speed control servo pulley. 3. Disconnect the speed control servo electrical connector. ^ Depress the connector tab. ^ Remove the connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 9793 4. Remove the speed control servo and bracket. 1 Remove the bolts. 2 Remove the speed control servo and bracket. NOTE: Do not remove the rubber grommets from the speed control servo bracket. 5. Remove the speed control servo bracket. 1 Remove the screws. 2 Remove the speed control servo bracket. INSTALLATION 1. Install the speed control servo bracket. NOTE: The rubber grommets must be correctly seated in the speed control servo bracket for correct noise and vibration isolation. 2. Install the speed control servo. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 9794 3. Insert the speed control cable slug into the speed control servo pulley slot. 1 Gently compress the speed control servo spring. 2 Insert the speed control cable slug into the speed control servo pulley slot. 4. Release the compressed spring while aligning the speed control actuator cable cap tabs with the slots in the speed control servo housing. NOTE: ^ Make sure the rubber seal is fully seated onto the speed control actuator cable cap. ^ Incorrect wrapping of the speed control actuator cable around the speed control servo pulley may result in a high idle condition. 5. Rotate the speed control actuator cable cap until the locking arm engages. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair Cruise Control Servo Cable: Service and Repair REMOVAL NOTE: 5.4L 2 Valve Triton V8 shown; others are similar. 1. Remove the accelerator control splash shield. 1 Remove the screws. 2 Remove the accelerator control splash shield. 2. Remove the speed control actuator cable. 1 Open the throttle valve. 2 Slide the throttle cable to remove from the throttle cam nail head. 3 Squeeze the speed control actuator cable tabs and remove from the accelerator bracket. 3. Remove the speed control actuator cable cap from the speed control servo. 1 Push in the locking arm on the speed control actuator cable cap. 2 Rotate the speed control actuator cable cap counterclockwise and remove the speed control actuator cable cap from the speed control servo. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair > Page 9798 4. Remove the speed control actuator cable. 1 Depress the spring retainer. 2 Slide the core wire end out of the speed control servo pulley and remove the speed control actuator cable. 5. Remove the cable from the retainer clips. INSTALLATION 1. Insert the speed control cable slug into the speed control servo pulley slot. 1 Gently compress the speed control servo spring. 2 Insert the speed control cable slug into the speed control servo pulley slot. 2. Release the compressed spring while aligning the speed control actuator cable cap tabs with the slots in the speed control servo housing NOTE: ^ Make sure the rubber seal is fully seated onto the speed control actuator cable cap. ^ Incorrect wrapping of the speed control actuator cable around the speed control servo pulley may result in a high idle condition. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair > Page 9799 3. Rotate the speed control actuator cable cap until the locking arm engages. 4. Install the speed control actuator cable. 1 Open the throttle valve. 2 Install the speed control cable to the throttle valve. 3 Install the speed control cable to the bracket. NOTE: Make sure the speed control cable is installed to all cable retainer clips. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 9813 Cruise Control Switch: Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 9814 Cruise Control Switch: Service and Repair REMOVAL 1. Remove the driver side air bag module. Refer to Air Bag Systems. 2. Remove the speed control actuator switch. 1 Release the four (A) speed control actuator switch clips and remove the (B) speed control actuator switch. 2 Disconnect the speed control actuator switch electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9824 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9825 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9826 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9827 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9828 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9829 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9830 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9831 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9832 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9833 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9834 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9835 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9836 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9837 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9838 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9839 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9840 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9841 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9842 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9843 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9844 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9845 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9846 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9847 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9848 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9849 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9854 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA05V017000 > Jan > 05 > Recall 05V017000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): Recalls Recall 05V017000: Cruise Control Deactivation Switch MAKE/MODELS: MODEL/BUILD YEARS: Ford/Expedition 2000 Ford/F150 2000 Ford/Supercrew 2001 Lincoln/Navigator 2000 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V017000 RECALL DATE: Jan 27, 2005 COMPONENT: Vehicle Speed Control: Cruise Control POTENTIAL NUMBER OF UNITS AFFECTED: 738490 SUMMARY: On certain sport utility vehicles and pickup trucks, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: This condition could lead to a fire. Fires have occurred while the vehicles were parked with the ignition "OFF." REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (early April 2005), Owners will be instructed to return to the dealers for installation of a new switch. Owners should contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9868 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9869 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9870 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9871 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9872 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9873 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9874 Attachment III - Technical Information Table of Contents Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9875 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9876 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9877 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9878 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9879 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9880 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9881 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9882 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9883 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9884 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9885 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9886 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9887 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9888 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9889 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9890 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9891 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9892 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 9893 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 9898 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA05V017000 > Jan > 05 > Recall 05V017000: Cruise Control Deactivation Switch Brake Switch (Cruise Control): All Technical Service Bulletins Recall 05V017000: Cruise Control Deactivation Switch MAKE/MODELS: MODEL/BUILD YEARS: Ford/Expedition 2000 Ford/F150 2000 Ford/Supercrew 2001 Lincoln/Navigator 2000 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V017000 RECALL DATE: Jan 27, 2005 COMPONENT: Vehicle Speed Control: Cruise Control POTENTIAL NUMBER OF UNITS AFFECTED: 738490 SUMMARY: On certain sport utility vehicles and pickup trucks, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: This condition could lead to a fire. Fires have occurred while the vehicles were parked with the ignition "OFF." REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (early April 2005), Owners will be instructed to return to the dealers for installation of a new switch. Owners should contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-327-4236. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 9907 Brake Switch (Cruise Control): Specifications Deactivator Switch 18 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information Brake Switch (Cruise Control): Technician Safety Information WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Technician Safety Information > Page 9910 Brake Switch (Cruise Control): Vehicle Damage Warnings 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. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 9911 Brake Switch (Cruise Control): Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions > Page 9912 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the deactivator switch electrical connector. 3. Remove the deactivator switch. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. INSTALLATION 1. To install, reverse the removal procedure. NOTE: After the deactivator switch is installed, it is necessary to bleed the brake system; refer to Brakes. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 9929 Cruise Control Switch: Testing and Inspection Additional Diagnosis For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Cruise Control; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 9930 Cruise Control Switch: Service and Repair REMOVAL 1. Remove the driver side air bag module. Refer to Air Bag Systems. 2. Remove the speed control actuator switch. 1 Release the four (A) speed control actuator switch clips and remove the (B) speed control actuator switch. 2 Disconnect the speed control actuator switch electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set Audible Warning Device: Customer Interest Ignition Switch - High Turning Effort/MIL ON/DTC's Set Article No. 01-21-13 10/29/01 ^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH ^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001 EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER ISSUE Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent conditions: ^ Roughness and/or excessive effort in turning the key from RUN to START position. ^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent accessory function. ^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory. This may be caused by a Key-In-Ignition warning chime switch. ACTION Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable and wait at least one minute. 2. Insent the ignition key and turn it to the RUN position. 3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock cylinder) and press the release button while pulling out the ignition switch lock cylinder. NOTE SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS REQUIRED. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 9940 4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model Workshop Manual, Key-in-ignition warning switch removal and installation section located in Section 413 if additional detail is required. 5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder. 6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime switch. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012113A Replace The 0.3 Hr. Key-In-Ignition Warning Chime Switch DEALER CODING CONDITION BASIC PART NO. CODE 11A127 42 OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set Audible Warning Device: All Technical Service Bulletins Ignition Switch - High Turning Effort/MIL ON/DTC's Set Article No. 01-21-13 10/29/01 ^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH ^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001 EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER ISSUE Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent conditions: ^ Roughness and/or excessive effort in turning the key from RUN to START position. ^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent accessory function. ^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory. This may be caused by a Key-In-Ignition warning chime switch. ACTION Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable and wait at least one minute. 2. Insent the ignition key and turn it to the RUN position. 3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock cylinder) and press the release button while pulling out the ignition switch lock cylinder. NOTE SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS REQUIRED. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 9946 4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model Workshop Manual, Key-in-ignition warning switch removal and installation section located in Section 413 if additional detail is required. 5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder. 6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime switch. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012113A Replace The 0.3 Hr. Key-In-Ignition Warning Chime Switch DEALER CODING CONDITION BASIC PART NO. CODE 11A127 42 OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9949 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9950 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9951 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9952 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9953 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9954 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9955 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9956 Audible Warning Device: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9957 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9958 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9959 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9960 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9961 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9962 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9963 Audible Warning Device: Electrical Diagrams Diagram 66-1 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 9964 Diagram 66-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 9965 Audible Warning Device: Description and Operation The warning device system consists of the following: ^ safety belt warning lamp switch ^ door ajar switch ^ Generic Electronic Module (GEM) ^ key-in-ignition warning switch ^ headlamp on warning ^ low washer fluid warning Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 9966 Audible Warning Device: Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Service and Repair > Door Ajar Switch Audible Warning Device: Service and Repair Door Ajar Switch For additional information, refer to Power Locks. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Service and Repair > Door Ajar Switch > Page 9969 Audible Warning Device: Service and Repair Key In Ignition Warning Switch REMOVAL 1. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pulling out the ignition switch lock cylinder. 2. Remove the key-in-ignition warning switch. 1 Pry the clip down. 2 Push the key-in-ignition warning switch off the rear of the ignition switch lock cylinder. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Service and Repair > Door Ajar Switch > Page 9970 1. To install, reverse the removal procedure. ^ Verify ignition switch lock cylinder operation. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Service and Repair > Door Ajar Switch > Page 9971 Audible Warning Device: Service and Repair Generic Electronic Module For additional information, refer to Multifunction Electronic Control Module. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9976 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9977 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9978 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9979 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9980 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9981 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9982 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9983 Audible Warning Device Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9984 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9985 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9986 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9987 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9988 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9989 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Testing and Inspection Charge Lamp/Indicator: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9997 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9998 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9999 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10000 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10001 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10002 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10003 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10004 Cigarette Lighter: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10005 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10006 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10007 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10008 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10009 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10010 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10011 Diagram 44-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Specifications Clock: Specifications Clock Screws 1.0-2.55 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions Clock: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 10017 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 10018 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 10019 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 10020 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 10021 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 10022 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 10023 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 10024 Clock: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 10025 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 10026 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 10027 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 10028 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 10029 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 10030 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 10031 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 10032 Diagram 44-3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Page 10033 Clock: Description and Operation The electric clock, centrally located on the instrument panel, displays time in a 12 hour format. The display illuminates when the ignition switch is in ACC or RUN and dims when the headlights are on. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Clock: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the electric clock. 2. Visually inspect for obvious signs of mechanical and/or electrical damage using the chart: VISUAL INSPECTION CHART 3. If an obvious cause for an observed or reported malfunction is found, correct the cause (if possible) before proceeding to the next step. 4. If the fault is not visually evident, verify the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10036 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10037 Clock: Pinpoint Tests Connector Circuit Reference Refer to the Vehicle/Diagrams for schematic and connector information. Test A: Clock Operation Is Erratic/Inoperative A1 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10038 A2 - A3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10039 A4 - A5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10040 A6 - A7 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Page 10041 Clock: Service and Repair REMOVAL 1. Release the clip and remove the electric clock and housing from the instrument panel. NOTE: The electric clock is held in place by spring clips located on the back of the housing. 2. Disconnect the electric clock electrical connector. 3. Remove the two screws and remove the electric clock from the housing. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection > Page 10042 Special Service Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Directional Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Directional Sensor > Component Information > Locations > Page 10047 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Supplemental Restraint System ( SRS ) Depowering and Repowering Depowering Procedure Warning: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Warning: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F22 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. Warning: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 6. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 1. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse F22 (10A) to the CJB and close the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 4. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10053 The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Deactivation and Reactivation Supplemental Restraint System ( SRS ) Deactivation and Reactivation Special Tool(s) Deactivation Warning: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Warning: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. Warning: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Warning: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. Warning: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All Vehicles 1. Move and tilt the front seats to their highest and most forward position. 2. Turn all vehicle accessories OFF. 3. Turn the ignition switch to OFF. 4. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F22 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 5. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 6. Turn the ignition OFF. Warning: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10054 The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 7. Disconnect the battery ground cable (14301) and wait at least one minute. 8. Remove the two steering wheel back cover plugs. 9. Remove the two driver air bag module retaining bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10055 10. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Disconnect the horn switch electrical connector. 3. Remove the driver air bag module. 11. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10056 12. Remove the instrument panel relay cover. 13. Disconnect the passenger air bag module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10057 14. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicle without side airbags Caution: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. 15. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM) If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with side airbags 16. Disconnect the passenger seat side air bag electrical connector. 1. Slide and disengage the passenger seat side air bag electrical connector locking clip. 2. Push in to release the tab and disconnect the passenger seat side air bag electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10058 17. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 18. Disconnect the driver seat side air bag electrical connector. 1. Slide and disengage the driver seat side air bag electrical connector locking clip. 2. Push in to release the tab and disconnect the driver seat side air bag electrical connector. 19. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All Vehicles 20. Install the RCM fuse F22 (10A) to the CJB. 21. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10059 Reactivation All Vehicles 1. Remove the RCM fuse F22 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles with side airbags 3. Remove the restraint system diagnostic tool from the driver side seat air bag floor electrical connector. 4. Connect the driver seat side air bag electrical connector. 1. Connect the driver seat side air bag electrical connector. 2. Slide and engage the driver seat side air bag electrical connector locking clip. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10060 5. Remove the restraint system diagnostic tool from the passenger side seat air bag floor electrical connector. 6. Connect the passenger side seat air bag electrical connector. 1. Connect the passenger side seat air bag electrical connector. 2. Slide and engage the passenger side seat air bag electrical connector locking clip. All Vehicles 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10061 8. Connect the passenger air bag module electrical connector. 9. Install the instrument panel relay cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10062 10. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Connect and position the driver air bag module. 1. Connect the horn switch electrical connector. 2. Connect the driver air bag module electrical connector. 3. Position the driver air bag module to the steering wheel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10063 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 14. 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. 15. Turn the ignition switch from OFF to ON. 16. Install the RCM fuse F22 (10A) to the CJB and close the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 17. Connect the battery ground cable. 18. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10064 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Is the air bag system connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Are the side air bag electrical connectors beneath the front seats connected? 4. Is the Restraints Control Module (RCM) connected? 5. Is the vehicle battery connected? Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Testing and Inspection Door/Trunk Ajar Indicator/Lamp: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair Door Switch: Service and Repair For additional information, refer to Body and Frame; Doors, Hood and Trunk. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation Driver/Vehicle Information Display: Description and Operation NOTE: ^ The Distance To Empty (DTE) display may be inaccurate if the vehicle is started while parked on an incline. ^ Fuel fills of less than 22.7 liters (6 gallons) may not be detected by the message center. ^ The instantaneous (INST) fuel economy feature is only available on early production vehicles. The message center uses inputs from the fuel level sensor and pump, the compass sensor module and the Powertrain Control Module (PCM). The input from the PCM is the vehicle speed signal. The PCM gets the vehicle speed signal from the Output Shaft Speed (OSS) sensor. From those inputs, the message center displays: ^ compass direction. ^ DTE. ^ average (AVG) fuel economy. ^ INST fuel economy (if equipped). Average (AVG) Fuel Economy - Resetting NOTE: Only the AVG fuel economy can be reset. DTE and INST displays cannot be reset. The AVG fuel economy display is resettable. To reset, the ignition switch must be in the RUN position (with or without the engine running) and the message center must be in the AVG fuel economy display mode. Press and release the MODE and E/M buttons simultaneously. If the vehicle is parked while resetting, the AVG fuel economy will display 0.0 (English mode) or 99.9 (metric mode). If the vehicle is in motion, the AVG fuel economy will display the current INST fuel economy (English mode or metric mode). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 10074 Driver/Vehicle Information Display: Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center Assembly Driver/Vehicle Information Display: Service and Repair Message Center Assembly REMOVAL 1. Open the overhead sunglasses compartment and remove the screw. 2. Grasp the front of the overhead console and pull down to remove the console. 3. Disconnect the electrical connectors. 4. Remove the message center. 1 Depress the lock tab underneath the in-line electrical connector. 2 Remove the in-line connector. 3 Remove the screws. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center Assembly > Page 10077 4 Remove the message center. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center Assembly > Page 10078 Driver/Vehicle Information Display: Service and Repair Vehicle Demagnetizing 1. CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a cloth over the vehicle's roof to protect the vehicle's surface if contact occurs. Make sure the cloth covers the front third and the entire width of the roof. NOTE: ^ The demagnetizing process requires the use of a demagnetizing coil commonly used by television service technicians to demagnetize television tubes. ^ To demagnetize, use a constant circular motion over the vehicle's roof. Do not turn off the demagnetizer while sweeping the vehicle's roof to prevent remagnetizing ferrous materials contained in the vehicle. ^ During the demagnetizing process, make sure the phenolic surface of the tool (the side opposite the handle) is closest to the vehicle's surface. 2. Demagnetize the front third of the vehicle's roof. 1 Turn on the demagnetizer at least 1 meter (3 ft) away from the vehicle. 2 Holding the demagnetizer no more than 2.5 cm (1 in) from the roof and starting on the passenger side, demagnetize the front third of the roof closest to the windshield using a constant circular motion. Keep the circle's radius within 30 cm (12 in) while sweeping across the entire surface of the roof closest to the windshield. Continue the circular motion four times. 3 After the fourth pass and without stopping, move the demagnetizer at least 1 meter (3 ft) away from the vehicle. 4 Turn the demagnetizer off. 3. Demagnetize the inside rear view mirror mounting pad. NOTE: The demagnetizer must be located over the outside of the windshield no greater than 2.5 cm (1 in). 1 Turn on the demagnetizer at least 1 meter (3 ft) away from the vehicle. 2 Using a circular motion, pass the demagnetizer over the outside of the windshield near the inside rear view mirror mounting pad. Without stopping, move the demagnetizer at least 1 meter (3 ft) away from the vehicle. 3 Turn the demagnetizer off. 4. Carry out the Compass Zone Adjustment procedure; refer to Compass Zone Adjustment. See: Compass/Adjustments/Compass Zone Adjustment 5. Carry out the Calibration Adjustment procedure; refer to Calibration Adjustment. See: Compass/Adjustments/Calibration Adjustment Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 10079 Special Service Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 10088 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 10094 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module > Component Information > Testing and Inspection Fuel Gauge Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation Fuel Gauge Sender: Description and Operation The "Gasoline System" information is not available at this time. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Depowering and Repowering Supplemental Restraint System ( SRS ) Depowering and Repowering Depowering Procedure Warning: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Warning: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F22 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. Warning: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 6. Disconnect the battery ground cable (14301) and wait at least one minute. Repowering Procedure Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 1. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 2. Turn the ignition switch from OFF to ON. 3. Install the RCM fuse F22 (10A) to the CJB and close the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 4. Connect the battery ground cable. 5. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10107 The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Deactivation and Reactivation Supplemental Restraint System ( SRS ) Deactivation and Reactivation Special Tool(s) Deactivation Warning: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Warning: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. Warning: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. Warning: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. Warning: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. Warning: To reduce the risk of personal injury, do not use any memory saver devices. Note: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered. Note: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Note: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All Vehicles 1. Move and tilt the front seats to their highest and most forward position. 2. Turn all vehicle accessories OFF. 3. Turn the ignition switch to OFF. 4. At the central junction box (CJB), located below the LH side of the instrument panel, remove the cover and the restraints control module (RCM) fuse F22 (10A) from the CJB. For additional information, refer to the Wiring Diagram Manual. 5. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 6. Turn the ignition OFF. Warning: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10108 The side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 7. Disconnect the battery ground cable (14301) and wait at least one minute. 8. Remove the two steering wheel back cover plugs. 9. Remove the two driver air bag module retaining bolts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10109 10. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector. 2. Disconnect the horn switch electrical connector. 3. Remove the driver air bag module. 11. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10110 12. Remove the instrument panel relay cover. 13. Disconnect the passenger air bag module electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10111 14. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector. Vehicle without side airbags Caution: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor connector. 15. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM) If a restraint system diagnostic tool is installed at the side air bag floor connector, a low resistance fault will be generated by the RCM. Vehicles with side airbags 16. Disconnect the passenger seat side air bag electrical connector. 1. Slide and disengage the passenger seat side air bag electrical connector locking clip. 2. Push in to release the tab and disconnect the passenger seat side air bag electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10112 17. Attach the restraint system diagnostic tool to the passenger seat side air bag floor electrical connector. 18. Disconnect the driver seat side air bag electrical connector. 1. Slide and disengage the driver seat side air bag electrical connector locking clip. 2. Push in to release the tab and disconnect the driver seat side air bag electrical connector. 19. Attach the restraint system diagnostic tool to the driver seat side air bag floor electrical connector. All Vehicles 20. Install the RCM fuse F22 (10A) to the CJB. 21. Connect the battery ground cable. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10113 Reactivation All Vehicles 1. Remove the RCM fuse F22 (10A) from the CJB. 2. Disconnect the battery ground cable and wait at least one minute. Vehicles with side airbags 3. Remove the restraint system diagnostic tool from the driver side seat air bag floor electrical connector. 4. Connect the driver seat side air bag electrical connector. 1. Connect the driver seat side air bag electrical connector. 2. Slide and engage the driver seat side air bag electrical connector locking clip. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10114 5. Remove the restraint system diagnostic tool from the passenger side seat air bag floor electrical connector. 6. Connect the passenger side seat air bag electrical connector. 1. Connect the passenger side seat air bag electrical connector. 2. Slide and engage the passenger side seat air bag electrical connector locking clip. All Vehicles 7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10115 8. Connect the passenger air bag module electrical connector. 9. Install the instrument panel relay cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10116 10. Remove the restraint system diagnostic tool from the vehicle harness side of the clockspring electrical connector at the top of the steering column. 11. Connect and position the driver air bag module. 1. Connect the horn switch electrical connector. 2. Connect the driver air bag module electrical connector. 3. Position the driver air bag module to the steering wheel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10117 12. Install the two driver air bag module retaining bolts. 13. Install the two steering wheel back cover plugs. Warning: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. 14. 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. 15. Turn the ignition switch from OFF to ON. 16. Install the RCM fuse F22 (10A) to the CJB and close the cover. Warning: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. 17. Connect the battery ground cable. 18. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will either: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a scan tool. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10118 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist below should be completed following diagnosis or repair of any air bag system concern. 1. Is the air bag system connector at the base of the steering column connected? 2. Are the air bag modules connected? 3. Are the side air bag electrical connectors beneath the front seats connected? 4. Is the Restraints Control Module (RCM) connected? 5. Is the vehicle battery connected? Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair Instrument Panel Bulb: Service and Repair REMOVAL 1. Remove the instrument cluster. 2. Remove the necessary instrument cluster bulb(s). ^ Remove the back cover if necessary. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10130 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10131 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10132 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10138 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10139 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10140 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Page 10141 Instrument Panel Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel Illumination Control Module > Component Information > Testing and Inspection Panel Illumination Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation SERVICE ENGINE SOON Your vehicle is equipped with a computer that monitors the engine's emission control system. This is commonly known as the On Board Diagnostic System (OBD II). This OBD II system protects the environment by ensuring that your vehicle continues to meet government emission standards. The OBD II system also assists the service technician in properly servicing your vehicle. The SERVICE ENGINE SOON indicator light illuminates when the ignition is first turned to the ON position to check the bulb. If it comes on after the engine is started, on of the engine's emission control systems may be malfunctioning. The light may illuminate without a driveability concern being noted. The vehicle will ususally be drivable and will not require towing. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation > Page 10148 Maintenance Required Lamp/Indicator: Service and Repair Solid SERVICE ENGINE SOON light This means that the On Board Diagnostic System (OBD II) has detected a malfunction. Temporary malfunctions may cause your SERVICE ENGINE SOON light to illuminate. Examples are: 1. The vehicle has run out of fuel. (The engine may misfire or run poorly.) 2. Poor fuel quality or water in the fuel. 3. The fuel cap may not have been properly installed and securely tightened. The temporary malfunctions can be corrected by filling the fuel tank with good quality fuel and/or properly installing and securely tightening the gas cap. After three driving cycles with out these or any other temporary malfunctions present, the SERVICE ENGINE SOON light should turn off. (A driving cycle consists of a cold engine start-up followed by mixed city/highway driving.) No additional vehicle service is required. Blinking SERVICE ENGINE SOON light Engine misfire is occurring which could cause damage to your catalytic converter. You should drive in a moderate fashion (avoid heavy acceleration and deceleration) and have your vehicle serviced at the first available opportunity. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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) Schematic CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol The Malfunction Indicator Lamp (MIL) alerts the driver that the Powertrain Control Module (PCM) has detected an On Board Diagnostic (OBD) II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. ^ The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol. ^ Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. ^ The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. ^ If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. ^ If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. ^ To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. ^ For any MIL concern Symptom Charts. ^ If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. ^ If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair The manufacturer does NOT show that this vehicle is equipped with an oil change reminder lamp. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Gauge: Customer Interest Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 10163 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Gauge: All Technical Service Bulletins Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 10169 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Page 10170 Oil Pressure Gauge: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Sender: Customer Interest Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 10179 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Sender: All Technical Service Bulletins Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 10185 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Specifications Parking Brake Warning Switch: Specifications Parking brake signal switch screw ..................................................................................................................................................... 2-3 Nm (18-27 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10194 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10195 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10196 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10197 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10198 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10199 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10200 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10201 Audible Warning Device Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10202 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10203 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10204 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10205 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10206 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10207 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Testing and Inspection Fuel Gauge Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10219 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10220 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10221 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10227 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10228 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10229 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Page 10230 Instrument Panel Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Panel Illumination Control Module > Component Information > Testing and Inspection Panel Illumination Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Speedometer Module: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 10242 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Speedometer Module: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 10248 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Testing and Inspection Seat Belt Reminder Lamp: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Directional Sensor > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Directional Sensor > Component Information > Locations > Page 10256 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair Door Switch: Service and Repair For additional information, refer to Body and Frame; Doors, Hood and Trunk. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation Fuel Gauge Sender: Description and Operation The "Gasoline System" information is not available at this time. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Specifications Parking Brake Warning Switch: Specifications Parking brake signal switch screw ..................................................................................................................................................... 2-3 Nm (18-27 ft. lbs.) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the transmission control selector lever in the (D) position. - Rotate the transmission control selector lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D) position). 3. Hang an eight pound weight on the transmission control selector lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the shift control selector lever from detent to detent and compare with transmission settings. - Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Speedometer Module: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 10277 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Speedometer Module: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 10283 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Testing and Inspection Tachometer: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Water temperature indicator sender unit 15 ft.lb Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Specifications > Page 10293 Temperature Sensor (Gauge): Description and Operation Engine Coolant Temperature Gauge Engine coolant temperature information is received by the instrument cluster from the PCM over the SCP network. Temperatures over 121°C (275°F) will display hot (H). If the engine coolant temperature data is missing or invalid for five seconds, the instrument cluster will move the engine coolant temperature gauge below the cold (C) position. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Testing and Inspection Volt Meter Gauge: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that is a part of, please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Reversing Lamp <--> [Backup Lamp] > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Reversing Lamp <--> [Backup Lamp] > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Diagrams > 4R70W Transmission Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Reversing Lamp <--> [Backup Lamp] > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Diagrams > 4R70W Transmission > Page 10304 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 10313 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 10319 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10322 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10323 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10324 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10325 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10326 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10327 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10328 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10329 Brake Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10330 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10331 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10332 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10333 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10334 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10335 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10336 Brake Lamp: Electrical Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 1. Verify the customer concern by operating the stoplamps. 2. Visually inspect for the following obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10339 Brake Lamp: Symptom Related Diagnostic Procedures NOTE: Refer to the Vehicle/Diagrams for connector numbers stated in the pinpoint test. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10340 Brake Lamp: Pinpoint Tests H1 - H2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10341 I1 - I2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10342 J1 - J2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page 10343 73III Automotive Meter Or Equivalent Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 10347 Brake Light Switch: Description and Operation Brake Pedal Position Switch Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 10348 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the Brake Pedal Position (BPP) switch connector. 2. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the spacer. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > Customer Interest for High Mounted Stoplamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling High Mounted Stoplamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > Customer Interest for High Mounted Stoplamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling > Page 10357 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for High Mounted Stoplamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling High Mounted Stoplamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for High Mounted Stoplamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 10363 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > High Mounted Stoplamp <--> [Center Mounted Brake Lamp] > Component Information > Technical Service Bulletins > Page 10364 High Mounted Stoplamp: Service and Repair REMOVAL 1. Remove the window glass moulding; refer to Windows. 2. Remove the high mounted stoplamp assembly. 1 Remove the screws. 2 Remove the high mounted stoplamp assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations Courtesy Lamp Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations > Page 10369 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations > Page 10370 The interior lamp relay is located in the central junction box under the left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations > Page 10371 Courtesy Lamp Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction Glove Box Lamp: Technical Service Bulletins Battery Saver Relay - Malfunction Article No. 00-19-2 09/18/00 ^ LAMP - COURTESY, GLOVE COMPARTMENT, UNDERHOOD, RUNNING BOARD LAMPS INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ POWER WINDOWS - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ RADIO - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ REAR WIPER - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES FORD: 1999-2000 EXPEDITION, F-150, F-250 LD LINCOLN: 1999-2000 NAVIGATOR This article is being republished in its entirety to update the part number. ISSUE A temporary loss of functions controlled by the battery saver relay may occur on some vehicles. These functions may be inoperative for a short period of time after the vehicle has sat unattended for at least 45 minutes. These functions are limited to courtesy and interior/demand lamps, glove compartment, underhood lamps and power windows. Running board lights, moonroof and the rear wiper may be affected on Expedition and Navigator. The radio may also be inoperative during this time on Navigator only. The loss of these features is temporary and can last from a few seconds up to 10-15 minutes. ACTION Replace the Battery Saver Relay (YL3Z-14N089-AA). Refer to the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) for location of this relay. NOTE PERMANENT LOSS OF ANY OF THESE FUNCTIONS SHOULD NOT BE ADDRESSED WITH THIS TSB. FUNCTIONS OTHER THAN THOSE EXPLICITLY MENTIONED ABOVE THAT ARE REPORTED TO BE INOPERATIVE SHOULD NOT BE ADDRESSED WITH THIS TSB. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-8-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION / DESCRIPTION / TIME Table Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction > Page 10376 DEALER CODING OASIS CODES: 10200, 204000, 201100, 201200, 202000, 20300, 205000, 207000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Service and Repair Interior Light Switch: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the electrical connector. 2 Rotate the interior lamp switch counterclockwise to remove. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations Daytime Running Lamp Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Page 10384 Located in the Daytime Running Lamps Relay Block, which is located behind the left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Page 10385 Daytime Running Lamp Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction Battery Discharge Protection Relay: Technical Service Bulletins Battery Saver Relay - Malfunction Article No. 00-19-2 09/18/00 ^ LAMP - COURTESY, GLOVE COMPARTMENT, UNDERHOOD, RUNNING BOARD LAMPS INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ POWER WINDOWS - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ RADIO - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ REAR WIPER - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES FORD: 1999-2000 EXPEDITION, F-150, F-250 LD LINCOLN: 1999-2000 NAVIGATOR This article is being republished in its entirety to update the part number. ISSUE A temporary loss of functions controlled by the battery saver relay may occur on some vehicles. These functions may be inoperative for a short period of time after the vehicle has sat unattended for at least 45 minutes. These functions are limited to courtesy and interior/demand lamps, glove compartment, underhood lamps and power windows. Running board lights, moonroof and the rear wiper may be affected on Expedition and Navigator. The radio may also be inoperative during this time on Navigator only. The loss of these features is temporary and can last from a few seconds up to 10-15 minutes. ACTION Replace the Battery Saver Relay (YL3Z-14N089-AA). Refer to the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) for location of this relay. NOTE PERMANENT LOSS OF ANY OF THESE FUNCTIONS SHOULD NOT BE ADDRESSED WITH THIS TSB. FUNCTIONS OTHER THAN THOSE EXPLICITLY MENTIONED ABOVE THAT ARE REPORTED TO BE INOPERATIVE SHOULD NOT BE ADDRESSED WITH THIS TSB. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-8-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION / DESCRIPTION / TIME Table Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction > Page 10390 DEALER CODING OASIS CODES: 10200, 204000, 201100, 201200, 202000, 20300, 205000, 207000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 10391 Battery Discharge Protection Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 10392 The battery saver relay is located in the central junction box (CJB), under the left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 10393 Battery Discharge Protection Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair Door Switch: Service and Repair For additional information, refer to Body and Frame; Doors, Hood and Trunk. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Testing and Inspection Exterior Lighting Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Lighting and Horns; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service Precautions Fog/Driving Lamp Bulb: Service Precautions WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service Precautions > Page 10404 Fog/Driving Lamp Bulb: Service and Repair REMOVAL WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. NOTE: The fog lamp bulb should not be removed from the fog lamp until just before a replacement bulb is installed. Removing the bulb for an extended period of time may affect fog lamp bulb performance. Contaminants may enter the fog lamp where they can settle on the lens and reflector. Never turn on the fog lamps with the bulb removed. 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Disconnect the fog lamp bulb electrical connector. 3. Rotate the fog lamp socket counterclockwise and remove. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 10408 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 10409 Fog/Driving Lamp Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Warning Flasher: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 10414 Located in the Blower/Flasher Relay Block, which is located behind the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations > Page 10415 Hazard Warning Flasher: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 10419 Hazard Warning Switch: Description and Operation The steering column switches consist of the: ^ multifunction switch, which controls the: ^ turn signal. ^ hazard flasher. ^ windshield wiper/washer. ^ rear wiper/washer. ^ headlamp dimmer/flash-to-pass. ^ ignition switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Hazard Warning Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10422 Hazard Warning Switch: Diagnostic Trouble Code Descriptions Generic Electronic Module (GEM) DTC Index B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10423 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10424 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10425 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10426 P1836-P1891 Part 5 of 5 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10427 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10428 Part 3 of 3 GEM Active Command Index Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10429 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10430 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10431 Hazard Warning Switch: Pinpoint Tests Test A: No Communication With the Module-GEM Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10432 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10433 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10434 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10435 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10436 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10437 Hazard Warning Switch: Testing and Inspection Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Generic Electronic Module (GEM) DTC Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10438 B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10439 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10440 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10441 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10442 P1836-P1891 Part 5 of 5 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10443 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10444 Part 3 of 3 GEM Active Command Index Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10445 Part 2 of 2 Test A: No Communication With the Module-GEM Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10446 Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10447 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10448 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10449 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10450 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10451 Part 2 of 2 Component Tests and General Diagnostics Multifunction Switch Tests Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10452 Component Testing Procedure Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10453 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10454 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10455 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Page 10456 Hazard Warning Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Note: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Page 10457 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the multi function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the multi function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions Headlamp Bulb: Service Precautions WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Page 10462 Headlamp Bulb: Service and Repair REMOVAL WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. NOTE: The headlamp bulb should not be removed from the headlamp until just before a replacement bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the headlamps with the bulb removed from the headlamp. 1. Remove the headlamp assembly; refer to Headlamp. 2. Rotate the headlamp bulb retainer counterclockwise and remove. 3. Remove the headlamp bulb by pulling it straight out with a gentle up-and-down rocking motion. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Be sure the headlamp assembly is positioned correctly with the alignment pins inserted into the correct holes and onto the ribs of the reinforcement. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Autolamp Module <--> [Headlamp Control Module] > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Autolamp Module <--> [Headlamp Control Module] > Component Information > Locations > Page 10466 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Autolamp Module <--> [Headlamp Control Module] > Component Information > Locations > Page 10467 Autolamp Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Lighting and Horns; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10471 Headlamp Dimmer Switch: Description and Operation The steering column switches consist of the: ^ multifunction switch, which controls the: ^ turn signal. ^ hazard flasher. ^ windshield wiper/washer. ^ rear wiper/washer. ^ headlamp dimmer/flash-to-pass. ^ ignition switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Headlamp Dimmer Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10474 Headlamp Dimmer Switch: Diagnostic Trouble Code Descriptions Generic Electronic Module (GEM) DTC Index B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10475 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10476 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10477 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10478 P1836-P1891 Part 5 of 5 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10479 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10480 Part 3 of 3 GEM Active Command Index Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10481 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10482 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10483 Headlamp Dimmer Switch: Pinpoint Tests Test A: No Communication With the Module-GEM Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10484 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10485 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10486 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10487 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10488 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10489 Headlamp Dimmer Switch: Testing and Inspection Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Generic Electronic Module (GEM) DTC Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10490 B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10491 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10492 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10493 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10494 P1836-P1891 Part 5 of 5 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10495 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10496 Part 3 of 3 GEM Active Command Index Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10497 Part 2 of 2 Test A: No Communication With the Module-GEM Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10498 Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10499 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10500 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10501 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10502 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10503 Part 2 of 2 Component Tests and General Diagnostics Multifunction Switch Tests Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10504 Component Testing Procedure Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10505 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10506 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10507 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 10508 Headlamp Dimmer Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Note: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 10509 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the multi function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the multi function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Located in the RPO Relay Block #1, which is located in the dash, above the passenger air bag. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 10513 Headlamp Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams Main Light Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 10517 Main Light Switch: Service Precautions CAUTION: Cover the end of the tool with tape to prevent damage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 10518 Main Light Switch: Testing and Inspection Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 10519 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 10520 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 10521 Main Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable, For additional information, refer to Battery. 2. Insert a thin tool to remove the headlamp switch. CAUTION: Cover the end of the tool with tape to prevent damage. 3. Disconnect the electrical connectors. INSTALLATION 1. To install reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 10526 Located in the RPO Relay Block #1, which is located in the dash, above the passenger air bag. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 10527 Horn Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair Steering Wheel Pad Horn Switch REMOVAL AND INSTALLATION NOTE: The steering wheel pad horn switch is part of the driver side air bag module. For additional information, refer to Air Bag Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions Illuminated Entry Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10535 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10536 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10537 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10538 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10539 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10540 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10541 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10542 Illuminated Entry Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10543 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10544 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10545 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10546 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10547 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10548 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 10549 Illuminated Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Lighting and Horns; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations Interior Lighting Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 10553 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 10554 The interior lamp relay is located in the central junction box under the left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 10555 Interior Lighting Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10560 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10561 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10562 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10563 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10564 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10565 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10566 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10567 License Plate Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10568 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10569 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10570 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10571 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10572 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10573 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10574 License Plate Lamp: Electrical Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 10575 License Plate Lamp: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Parking Lamp; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair Map Light Bulb: Service and Repair REMOVAL 1. Remove the map lamp assembly. For additional information, refer to Map Light. 2. Release the clip on the bulb(s) to be replaced. 3. Remove the map lamp bulb. 1 Remove the map lamp reflector. 2 Remove the map lamp bulb from the clips. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10584 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10585 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10586 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10587 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10588 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10589 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10590 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10591 Marker Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10592 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10593 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10594 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10595 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10596 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10597 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10598 Marker Lamp: Electrical Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Located in the RPO Relay Block #1, which is located in the dash, above the passenger air bag. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 10603 Parking Lamp Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction Battery Discharge Protection Relay: Technical Service Bulletins Battery Saver Relay - Malfunction Article No. 00-19-2 09/18/00 ^ LAMP - COURTESY, GLOVE COMPARTMENT, UNDERHOOD, RUNNING BOARD LAMPS INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ POWER WINDOWS - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ RADIO - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ REAR WIPER - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES FORD: 1999-2000 EXPEDITION, F-150, F-250 LD LINCOLN: 1999-2000 NAVIGATOR This article is being republished in its entirety to update the part number. ISSUE A temporary loss of functions controlled by the battery saver relay may occur on some vehicles. These functions may be inoperative for a short period of time after the vehicle has sat unattended for at least 45 minutes. These functions are limited to courtesy and interior/demand lamps, glove compartment, underhood lamps and power windows. Running board lights, moonroof and the rear wiper may be affected on Expedition and Navigator. The radio may also be inoperative during this time on Navigator only. The loss of these features is temporary and can last from a few seconds up to 10-15 minutes. ACTION Replace the Battery Saver Relay (YL3Z-14N089-AA). Refer to the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) for location of this relay. NOTE PERMANENT LOSS OF ANY OF THESE FUNCTIONS SHOULD NOT BE ADDRESSED WITH THIS TSB. FUNCTIONS OTHER THAN THOSE EXPLICITLY MENTIONED ABOVE THAT ARE REPORTED TO BE INOPERATIVE SHOULD NOT BE ADDRESSED WITH THIS TSB. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-8-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION / DESCRIPTION / TIME Table Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction > Page 10609 DEALER CODING OASIS CODES: 10200, 204000, 201100, 201200, 202000, 20300, 205000, 207000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 10610 Battery Discharge Protection Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 10611 The battery saver relay is located in the central junction box (CJB), under the left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 10612 Battery Discharge Protection Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations Courtesy Lamp Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 10616 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 10617 The interior lamp relay is located in the central junction box under the left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 10618 Courtesy Lamp Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations Daytime Running Lamp Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 10622 Located in the Daytime Running Lamps Relay Block, which is located behind the left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 10623 Daytime Running Lamp Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module > Component Information > Testing and Inspection Exterior Lighting Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Lighting and Horns; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 10630 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 10631 Fog/Driving Lamp Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Autolamp Module <--> [Headlamp Control Module] > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Autolamp Module <--> [Headlamp Control Module] > Component Information > Locations > Page 10635 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Autolamp Module <--> [Headlamp Control Module] > Component Information > Locations > Page 10636 Autolamp Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Lighting and Horns; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Located in the RPO Relay Block #1, which is located in the dash, above the passenger air bag. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 10640 Headlamp Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 10644 Located in the RPO Relay Block #1, which is located in the dash, above the passenger air bag. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 10645 Horn Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions Illuminated Entry Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10650 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10651 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10652 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10653 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10654 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10655 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10656 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10657 Illuminated Entry Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10658 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10659 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10660 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10661 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10662 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 10663 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Illuminated Entry Module <--> [Interior Lighting Module] > Component Information > Diagrams > Page 10664 Illuminated Entry Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Lighting and Horns; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations Interior Lighting Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 10668 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 10669 The interior lamp relay is located in the central junction box under the left side of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 10670 Interior Lighting Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Located in the RPO Relay Block #1, which is located in the dash, above the passenger air bag. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 10674 Parking Lamp Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Diagrams > 4R70W Transmission Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Reversing Lamp Switch <--> [Backup Lamp Switch] > Component Information > Diagrams > 4R70W Transmission > Page 10681 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 10685 Brake Light Switch: Description and Operation Brake Pedal Position Switch Typical Brake Pedal Position Switch The Brake Pedal Position (BPP) switch is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality. On most applications the BPP switch is hard wired to the PCM and supplies battery positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch signal is broadcast over the SCP link via another module to be received by the PCM. On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 10686 Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the Brake Pedal Position (BPP) switch connector. 2. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the spacer. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10695 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10696 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10697 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10698 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10699 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10700 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10701 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10702 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10703 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10704 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10705 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10706 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10712 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10713 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10714 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10715 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10716 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10717 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10718 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10719 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10720 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10721 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10722 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10723 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Page 10724 Multifunction Switch: Testing and Inspection For further information regarding this component please refer to Turn Signal Switch; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Page 10725 Multifunction Switch: Service and Repair For further information regarding this component please refer to Turn Signal Switch; Service and Repair. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair Door Switch: Service and Repair For additional information, refer to Body and Frame; Doors, Hood and Trunk. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 10732 Hazard Warning Switch: Description and Operation The steering column switches consist of the: ^ multifunction switch, which controls the: ^ turn signal. ^ hazard flasher. ^ windshield wiper/washer. ^ rear wiper/washer. ^ headlamp dimmer/flash-to-pass. ^ ignition switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Hazard Warning Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10735 Hazard Warning Switch: Diagnostic Trouble Code Descriptions Generic Electronic Module (GEM) DTC Index B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10736 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10737 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10738 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10739 P1836-P1891 Part 5 of 5 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10740 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10741 Part 3 of 3 GEM Active Command Index Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10742 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10743 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10744 Hazard Warning Switch: Pinpoint Tests Test A: No Communication With the Module-GEM Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10745 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10746 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10747 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10748 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10749 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10750 Hazard Warning Switch: Testing and Inspection Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Generic Electronic Module (GEM) DTC Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10751 B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10752 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10753 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10754 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10755 P1836-P1891 Part 5 of 5 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10756 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10757 Part 3 of 3 GEM Active Command Index Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10758 Part 2 of 2 Test A: No Communication With the Module-GEM Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10759 Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10760 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10761 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10762 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10763 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10764 Part 2 of 2 Component Tests and General Diagnostics Multifunction Switch Tests Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10765 Component Testing Procedure Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10766 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10767 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10768 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 10769 Hazard Warning Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Note: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 10770 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the multi function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the multi function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams Headlamp Dimmer Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 10774 Headlamp Dimmer Switch: Description and Operation The steering column switches consist of the: ^ multifunction switch, which controls the: ^ turn signal. ^ hazard flasher. ^ windshield wiper/washer. ^ rear wiper/washer. ^ headlamp dimmer/flash-to-pass. ^ ignition switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Headlamp Dimmer Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10777 Headlamp Dimmer Switch: Diagnostic Trouble Code Descriptions Generic Electronic Module (GEM) DTC Index B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10778 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10779 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10780 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10781 P1836-P1891 Part 5 of 5 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10782 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10783 Part 3 of 3 GEM Active Command Index Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10784 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10785 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10786 Headlamp Dimmer Switch: Pinpoint Tests Test A: No Communication With the Module-GEM Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10787 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10788 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10789 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10790 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10791 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10792 Headlamp Dimmer Switch: Testing and Inspection Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Generic Electronic Module (GEM) DTC Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10793 B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10794 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10795 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10796 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10797 P1836-P1891 Part 5 of 5 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10798 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10799 Part 3 of 3 GEM Active Command Index Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10800 Part 2 of 2 Test A: No Communication With the Module-GEM Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10801 Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10802 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10803 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10804 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10805 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10806 Part 2 of 2 Component Tests and General Diagnostics Multifunction Switch Tests Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10807 Component Testing Procedure Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10808 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10809 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10810 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 10811 Headlamp Dimmer Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Note: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 10812 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the multi function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the multi function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams Main Light Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 10816 Main Light Switch: Service Precautions CAUTION: Cover the end of the tool with tape to prevent damage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 10817 Main Light Switch: Testing and Inspection Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 10818 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 10819 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Main Light Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 10820 Main Light Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable, For additional information, refer to Battery. 2. Insert a thin tool to remove the headlamp switch. CAUTION: Cover the end of the tool with tape to prevent damage. 3. Disconnect the electrical connectors. INSTALLATION 1. To install reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair Steering Wheel Pad Horn Switch REMOVAL AND INSTALLATION NOTE: The steering wheel pad horn switch is part of the driver side air bag module. For additional information, refer to Air Bag Systems. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Service and Repair Interior Light Switch: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the interior lamp switch. 1 Disconnect the electrical connector. 2 Rotate the interior lamp switch counterclockwise to remove. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 10830 Turn Signal Switch: Description and Operation The steering column switches consist of the: ^ multifunction switch, which controls the: ^ turn signal. ^ hazard flasher. ^ windshield wiper/washer. ^ rear wiper/washer. ^ headlamp dimmer/flash-to-pass. ^ ignition switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Turn Signal Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10833 Turn Signal Switch: Diagnostic Trouble Code Descriptions Generic Electronic Module (GEM) DTC Index B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10834 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10835 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10836 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10837 P1836-P1891 Part 5 of 5 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10838 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10839 Part 3 of 3 GEM Active Command Index Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10840 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10841 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10842 Turn Signal Switch: Pinpoint Tests Test A: No Communication With the Module-GEM Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10843 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10844 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10845 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10846 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10847 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10848 Turn Signal Switch: Testing and Inspection Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Generic Electronic Module (GEM) DTC Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10849 B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10850 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10851 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10852 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10853 P1836-P1891 Part 5 of 5 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10854 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10855 Part 3 of 3 GEM Active Command Index Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10856 Part 2 of 2 Test A: No Communication With the Module-GEM Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10857 Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10858 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10859 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10860 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10861 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10862 Part 2 of 2 Component Tests and General Diagnostics Multifunction Switch Tests Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10863 Component Testing Procedure Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10864 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10865 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10866 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 10867 Turn Signal Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Note: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 10868 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the multi function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the multi function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10873 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10874 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10875 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10876 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10877 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10878 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10879 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10880 Tail Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10881 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10882 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10883 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10884 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10885 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10886 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10887 Tail Lamp: Electrical Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 10888 Tail Lamp: Testing and Inspection For further information regarding the diagnosis of this component and the system that it is part of, please refer to Parking Lamp; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 10889 Tail Lamp: Service and Repair REMOVAL 1. Raise the liftgate and remove the rear lamp screws. 2. Remove the rear lamp assembly. 1 Pull the rear lamp assembly outward. 2 Disconnect the electrical connector and remove the rear lamp assembly. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 10890 Special Service Tool(s) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) 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 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for the obvious signs of electrical damage. VISUAL INSPECTION CHART ^ Battery Junction Box(BJB) Fuse: 5 (20A) - 20 (10A) - 19 (10A) - 101 (30A) - 108 (30A) ^ Central Junction Box (CJB) Fuse 23 (10A) ^ CJB Fuse 13 (10A) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Bulb(s) 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10895 Trailer Lamps: Symptom Related Diagnostic Procedures NOTE: Refer to the Vehicle/Diagrams for connector numbers stated in the pinpoint test. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10896 Trailer Lamps: Pinpoint Tests Connector Circuit Reference Refer to the Vehicle/Diagrams for schematic and connector information. X1 - X2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10897 Y1 - Y2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10898 Y3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10899 Z1 - Z2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10900 Z3 Tests AA: The Trailer Lamps Are Inoperative - Trailer Parking Lamps Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10901 AA1 - AA2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10902 AA3 - AA4 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10903 AA5 Tests AB: Trailer Lamps Are Inoperative - Trailer Reversing Lamps Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10904 AB1 - AB2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10905 AB3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10906 AB4 - AB5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10907 AC1 - AC2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10908 AC3 - AC4 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10909 AD1 - AD2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10910 AD3 - AD5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10911 AE1 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10912 73III Automotive Meter Or Equivalent Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Page 10913 73III Automotive Meter Or Equivalent Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 10923 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 10924 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 10925 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 10926 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 10927 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 10928 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 10929 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 10930 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 10931 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 10932 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 10933 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Recalls for Multifunction Switch: > 00B40 > Apr > 00 > Recall Multifunction Switch Replacement > Page 10934 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement Technical Service Bulletin # 00B40 Date: 000401 Recall - Multifunction Switch Replacement 00B40 OWNER NOTIFICATION PROGRAM Certain 1999 and 2000 Model Year Explorer, Mountaineer, Ranger, Expedition, Navigator and Villager Vehicles - Multifunction Switch Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Attachment IV ^ Lincoln Commitment Special Handling Procedure Announcement Letter Customer Service Notification Letter Customer Notification Letter Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10940 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10941 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10942 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10943 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this program. PLEASE NOTE Correct all vehicles in stock before delivery. PROMPTLY CORRECT Promptly correct all affected vehicles on the enclosed list (if provided) or the VIN list in the Ford Dealership Consolidated Communicator (FDCC) and other eligible vehicles, which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and arrange for a service date. NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. - Refer to ACESII Manual for claims preparation and submission information. ^ To claim for the "Lincoln Commitment Special Handling", follow the instructions on page two of Attachment IV. OWNER REFUNDS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10944 Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Ford will pay for a loaner or rental vehicle for one (1) day except for fuel, which will be at the owner's expense.The one (1) day rental should be provided only while the vehicle is at the dealership for the multifunction switch replacement. If additional rental days are needed, the days will be taken from the dealers Transportation Assistance Program (TAP) allowance. Follow Extended Service Plan (ESP) guidelines for rental dollar amounts. Enter the word "LOANER" plus the number one (1) for the number of days the vehicle was used in the Miscellaneous Expense area of the claim NOTE: Navigator owners should receive the "Lincoln Commitment Special Handling Procedure". Before calling Navigator owners, review Attachment IV to familiarize yourself with the special handling procedure. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". Attachment II - Labor and Parts Information LABOR ALLOWANCES * Lincoln Commitment Special Handling does not apply to vehicles in dealer stock. PARTS REQUIREMENTS Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10945 Parts Ordering Information Parts will not be direct shipped for this program. Order your part requirements through normal order processing channels as noted below: DEALER PRICE For latest prices, check or call your: ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information MULTIFUNCTION SWITCH REPLACEMENT AFFECTED VEHICLES: CERTAIN 1999-2000 EXPLORER/MOUNTAINEER, RANGER, EXPEDITION/NAVIGATOR AND VILLAGER OVERVIEW When performing this service procedure, you will: ^ Replace the multifunction switch. ^ Check the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. MULTIFUNCTION SWITCH REPLACEMENT Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10946 1. Record the radio stations and disconnect the battery ground cable. NOTE: Steps 2 and 3 do not apply to Villager. Go to Step 4. 2. Turn the ignition switch lock cylinder to the RUN position. Then, push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder. 3. Remove the tilt wheel handle by turning the handle counterclockwise (if equipped). 4. Remove the upper to lower steering column shroud retaining screws and remove the shrouds. 5. Remove the two (2) multifunction switch retaining screws and disconnect the electrical connectors. See Figure 1. 6. Inspect the multifunction switch electrical connector pins to make sure they are not loose or pushed out in the connectors. See Figure 2. 7. Connect the new multifunction switch, making sure the electrical connectors snap into place and are fully seated. 8. Install the new switch. Tighten the screws to 3 Nm (27 lb-in). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10947 9. Install the upper and lower steering column shrouds. Tighten the screws to 1 Nm (9 lb-in). NOTE: Steps 10 and 11 do not apply to Villager. Go to Step 12. 10. Install the tilt wheel handle (if equipped). 11. Install the ignition switch lock cylinder. 12. Connect the battery ground cable, reprogram the radio stations and set the clock. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10948 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10949 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10950 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multifunction Switch: > 00B40 > Apr > 00 > Recall - Multifunction Switch Replacement > Page 10951 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Page 10952 Multifunction Switch: Testing and Inspection For further information regarding this component please refer to Turn Signal Switch; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Multifunction Switch <--> [Combination Switch] > Component Information > Technical Service Bulletins > Page 10953 Multifunction Switch: Service and Repair For further information regarding this component please refer to Turn Signal Switch; Service and Repair. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Turn Signal Flasher: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 10957 Located in the Blower/Flasher Relay Block, which is located behind the center of the instrument panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Page 10958 Turn Signal Flasher: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams For further information regarding this component please refer to: Lighting and Horns/Diagrams. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 10962 Turn Signal Switch: Description and Operation The steering column switches consist of the: ^ multifunction switch, which controls the: ^ turn signal. ^ hazard flasher. ^ windshield wiper/washer. ^ rear wiper/washer. ^ headlamp dimmer/flash-to-pass. ^ ignition switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Turn Signal Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10965 Turn Signal Switch: Diagnostic Trouble Code Descriptions Generic Electronic Module (GEM) DTC Index B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10966 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10967 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10968 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10969 P1836-P1891 Part 5 of 5 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10970 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10971 Part 3 of 3 GEM Active Command Index Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10972 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10973 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10974 Turn Signal Switch: Pinpoint Tests Test A: No Communication With the Module-GEM Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10975 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10976 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10977 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10978 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10979 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10980 Turn Signal Switch: Testing and Inspection Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Generic Electronic Module (GEM) DTC Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10981 B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10982 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10983 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10984 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10985 P1836-P1891 Part 5 of 5 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10986 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10987 Part 3 of 3 GEM Active Command Index Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10988 Part 2 of 2 Test A: No Communication With the Module-GEM Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10989 Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10990 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10991 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10992 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10993 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10994 Part 2 of 2 Component Tests and General Diagnostics Multifunction Switch Tests Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10995 Component Testing Procedure Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10996 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10997 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10998 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Page 10999 Turn Signal Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Note: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Page 11000 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the multi function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the multi function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction Underhood Lamp: Technical Service Bulletins Battery Saver Relay - Malfunction Article No. 00-19-2 09/18/00 ^ LAMP - COURTESY, GLOVE COMPARTMENT, UNDERHOOD, RUNNING BOARD LAMPS INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ POWER WINDOWS - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ RADIO - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ REAR WIPER - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES FORD: 1999-2000 EXPEDITION, F-150, F-250 LD LINCOLN: 1999-2000 NAVIGATOR This article is being republished in its entirety to update the part number. ISSUE A temporary loss of functions controlled by the battery saver relay may occur on some vehicles. These functions may be inoperative for a short period of time after the vehicle has sat unattended for at least 45 minutes. These functions are limited to courtesy and interior/demand lamps, glove compartment, underhood lamps and power windows. Running board lights, moonroof and the rear wiper may be affected on Expedition and Navigator. The radio may also be inoperative during this time on Navigator only. The loss of these features is temporary and can last from a few seconds up to 10-15 minutes. ACTION Replace the Battery Saver Relay (YL3Z-14N089-AA). Refer to the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) for location of this relay. NOTE PERMANENT LOSS OF ANY OF THESE FUNCTIONS SHOULD NOT BE ADDRESSED WITH THIS TSB. FUNCTIONS OTHER THAN THOSE EXPLICITLY MENTIONED ABOVE THAT ARE REPORTED TO BE INOPERATIVE SHOULD NOT BE ADDRESSED WITH THIS TSB. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-8-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION / DESCRIPTION / TIME Table Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Lighting and Horns > Underhood Lamp > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction > Page 11005 DEALER CODING OASIS CODES: 10200, 204000, 201100, 201200, 202000, 20300, 205000, 207000 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions Heated Glass Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11012 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11013 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11014 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11015 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11016 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11017 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11018 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11019 Heated Glass Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11020 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11021 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11022 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11023 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11024 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11025 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Control Module > Component Information > Diagrams > Page 11026 Heated Glass Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Windows; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 11030 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 11031 Heated Glass Element Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams > Page 11035 Heated Glass Element Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the steering column opening cover. NOTE: Position the gear shifter into low or drive 1 position. 3. Remove the headlamp switch. For additional information, refer to Lighting and Horns. 4. Remove the instrument panel finish panel. 1 Remove the panel bolts. 2 Remove the instrument panel finish panel. 5. Disconnect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams > Page 11036 6. Remove the rear window defrost switch. ^ Remove the screws. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair Rear Defogger: Technical Service Bulletins A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair TSB 04-24-5 12/13/04 REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR TERMINAL TAB REPAIR FORD: 1999-2000 Contour 1999-2002 Escort 1999-2003 Escort ZX2 1999-2005 Crown Victoria, Mustang, Taurus 2000-2005 Focus 2005 Five Hundred, Freestyle 1999-2003 Windstar 1999-2005 Expedition, Explorer 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape 2004-2005 F-150, Freestar 2005 Escape Hybrid LINCOLN: 1999-2002 Continental 1999-2005 Town Car 2000-2005 LS 1999-2005 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 1999 Tracer 1999-2000 Mystique 1999-2005 and Marquis, Sable 2005 Montego 1999-2002 Villager 1999-2005 Mountaineer 2004-2005 Monterey 2005 Mariner This article supersedes TSB 04-18-9 to update vehicle applications and service procedure. ISSUE Some vehicles may exhibit inoperative electric rear window defroster (heated back lite) grid lines, integral antenna concerns causing radio reception issues or terminal tabs pulled from the rear window glass. ACTION Follow the diagnostic and repair procedures included in this article to inspect and service rear defroster grid lines, integral antenna concerns or broken terminal tabs. SERVICE PROCEDURE Warrantable/Non Warrantable repairs Warrantable grid line repairs typically can be identified by one inoperative grid line with a small discoloration at the area of concern, approximately the size of a pinhead. Grid line(s) that are scratched or have the silver material removed are not warrantable and should be addressed with the customer. Replacement of backglass for grid line or bus bar tarnishing is not a warrantable repair. Tarnishing of the silver lines or bus bars is a normal condition. Please refer to the Heated Back Lite Damageability Job Aid for additional information and examples of defects and damage. NOTE THE GRID LINE MATERIAL IS NOT EMBEDDED INTO THE GLASS BUT IS BAKED TO THE GLASS SURFACE AND CONSEQUENTLY CAN BE SCRAPED OFF. INOPERATIVE LINES MAY APPEAR TO THE EYE TO BE UNDAMAGED DUE TO RESIDUE REMAINING ON Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11041 THE GLASS AND WILL REQUIRE DIAGNOSIS WITH A VOLTMETER OR 12V TEST LAMP AS EXPLAINED IN THIS ARTICLE. Examples Of Non-Warrantable Grid Line Damage ^ Ice scraper damage to grid lines ^ Animal scratches on grid lines ^ Window tint film/removal of the film which damages grid lines ^ Stickers placed over grids which upon removal, removes the grid line material ^ License plate (steel type placed against the inside of back glass) which rubs on the grid line causing damage ^ Temporary license plate (paper stuck on to the inside of the back glass) which upon removal removes grid line material ^ Cargo or lumber rubbing against the glass which removes grid line material ^ Cellular phone antenna installation/removal which damages grid line material NOTE AN UNDAMAGED GRIDLINE WILL HAVE SMALL RIDGES THAT PROJECT ABOVE THE SURFACE OF THE GLASS AND CAN EASILY BE FELT WHEN RUNNING A FINGERNAIL ACROSS THEM. GRIDLINES THAT HAVE BEEN "RAZOR BLADED" WILL FEEL SMOOTH WHEN A FINGERNAIL IS DRAGGED ACROSS THE AFFECTED AREA. THERE MAY BE SOME RESIDUE LEFT ON THE GLASS THAT APPEARS TO BE GRID MATERIAL BUT A CHECK WITH A VOLTMETER OR 12V TEST LAMP, AS EXPLAINED IN THIS ARTICLE, WILL CONFIRM AN OPEN CIRCUIT. GRID LINE INOPERATIVE - DIAGNOSTICS 1. Reference Workshop Manual Section 501-11 and the Wiring Diagram Section 56 to verify power and ground to the back-glass. 2. Connect a test lamp or DVOM to a good body ground. 3. Turn the ignition key to the run position and depress and release the rear defroster button to turn the system on. THE GRID IS ENERGIZED FOR APPROXIMATELY 10 MINUTES EACH TIME THE DEFROSTER BUTTON IS PRESSED. 4. Starting from the top grid line at the center of the back-glass, touch the test lamp or DVOM + lead to each grid line. (Use caution not to damage grid lines). The DVOM should read approximately 1/2 of the battery voltage on each line at the center of the back-glass. If using a test light, the bulb should be approximately the same brightness on each line from top to bottom. If the DVOM or light indicates a high voltage or no voltage on any grid line, move along the concern grid line with the + test lead or test lamp until the voltage changes suddenly. This is the area of concern, use chalk to mark the area of concern and mark the outside of the glass at that same area. 5. Repair per the Grid Line Repair Procedure. GRID LINE REPAIR PROCEDURE NOTE LONG GAPS ARE ALMOST ALWAYS DUE TO DAMAGE AND ARE NOT WARRANTABLE, HOWEVER THEY CAN BE REPAIRED. THE LONGER THE GAP THE MORE IMPORTANT IT IS TO APPLY A MINIMUM SIX (6) COATS OF CONDUCTIVE REPAIR MATERIAL WITH THE FIVE (5) MINUTE DRY TIME BETWEEN EACH COAT. APPLYING LESS COATS OR NOT ALLOWING DRY TIME BETWEEN COATS WILL PRODUCE REPAIRED RESISTANCE THAT IS GREATER THAN OEM RESISTANCE, RESULTING IN POOR DEFROST PERFORMANCE AND EXCESSIVE LOCALIZED HEATING. REPAIRED LONG GAPS ARE GENERALLY NOT VISUALLY PLEASING UNLESS EXTREME CARE IS TAKEN WHEN TAPING AFFECTED GRID LINE AREAS. NOTE IF THE BROWN COLOR UNDER THE GRID LINE IS DAMAGED OR MISSING (THIS IS VERY RARE), IT WILL BE NECESSARY TO APPLY BROWN ACRYLIC LACQUER TOUCH-UP PAINT FOR COLOR MATCH. THIS PAINT MUST MEET SPECIFICATION ESR-M2P100-C AND SHOULD BE APPLIED TO THE GLASS PRIOR TO APPLYING THE REAR WINDOW DEFROSTER REPAIR COMPOUND. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11042 Service inoperative grid lines on rear window glass using Motorcraft Defroster Repair PM-11 or equivalent meeting Ford specification ESB-M4J58-A as follows: Surface Preparation 1. Bring vehicle inside and warm it to 60° F (16° C) or above. 2. Do not use scrapers, sharp instruments, or abrasive window cleaners on the interior surface of the rear window glass as this may cause damage to the grid lines. Clean the entire grid line service area with Ultra Clear Spray Glass Cleaner ZC-23 or equivalent meeting Ford specification ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry. NOTE THE REPAIR AREA HOWEVER SHOULD BE CLEANED WITH STEEL WOOL OR AN ABRASIVE PAD SUCH AS SCOTCHBRITE TO REMOVE GRIME. Mixing The bottle of Rear Window Defroster Repair compound and touch-up paint (if needed) must be at room temperature. Shake the bottle for at least one (1) minute for thorough mixing. Shake frequently during use. Application 1. Mark location of open grid on the outside of the back window glass (performed in diagnostics). Place protective covering over the package tray as necessary. 2. Using "fine line tape", mask off the area directly above and below open grid line (Figure 1). It is best to extend the tape 26 mm (1") beyond the concern area in both directions. The open should be at the center of the mask and tape gap must be no wider than the existing grid line. Other types of tape may be used but end results of the repair may not appear as visually acceptable due to ease of application and tape edge finish. 3. If the brown layer of the grid is not broken or missing, apply only the silver grid repair compound to the open grid line. Apply the correct coating in several smooth continuous strokes (allowing five (5) minutes drying time between coats) across the open grid line area using the brush applicator in the cap. Extend the service coating at least 6 mm (.25") on both sides of the open grid line area. Apply a minimum of six (6) coats of the grid repair compound. 4. If both brown and silver layers of the grid are broken or missing, apply a coating of brown lacquer touch-up paint across the open line area first. Take care to paint only the area missing the color. Two (2) coats may be necessary to obtain the proper color. Allow the touch-up paint to dry at least five (5) minutes between coats. Apply six (6) coats of grid repair compound. NOTE THE INTERIOR SIDE OF THE GRID LINES ARE NOT PAINTED, BUT DUE TO THE SILVER TARNISHING WILL TEND TO CHANGE THE GRID TO A GOLD OR BROWN COLOR. THE REPAIRED AREA WILL BE BRIGHT SILVER AND WILL ALSO TARNISH OVER Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11043 TIME TO MATCH THE REST OF THE GRID. 5. After five (5) minutes of dry time of the final coat of grid repair compound, remove the tape, step outside and inspect the repaired area. If the repair compound is visible above or below the grid, the excess can be removed. This may be done by placing a single-edge razor blade on the back window glass parallel to grid and scrape gently toward grid. A wider/thicker line will perform better but may not be cosmetically appealing. CAUTION BE CAREFUL NOT TO DAMAGE GRID LINE WITH RAZOR BLADE. VERIFY ALL OF THE GRID LINES FUNCTION PROPERLY WHEN FINISHED. Curing The service coating will air-dry in approximately one (1) minute and the system can be energized after five minutes. Maximum hardness and adhesion occur after approximately 24 hours. SOLDER METHOD OF LEAD TERMINAL NOTE THE REAR WINDOW MUST BE AT A MINIMUM OF 60° F (16° C) BEFORE A REPAIR IS MADE. PLACE PROTECTIVE COVERING OVER THE PACKAGE TRAY AS NECESSARY. The new terminal will cover the original terminal location, but must be placed so that the new terminal conductive areas will be placed on a good conductive base. This area should be cleaned with steel wool or an abrasive pad to remove grime from the buss-bar. The area should then be cleaned with Ultra Clear Spray Glass Cleaner, ZC-23, or equivalent meeting Ford specification ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry and appear metallic. Depending on the buss-bar condition, rigorous polishing with steel wool may be required. Please note that the entire buss-bar may be cleaned to improve appearance. CAUTION DO NOT USE ANY TYPE OF FLAME TORCH OR FLAME HEATED SOLDERING GUN FOR THIS PROCEDURE. TESTING INDICATED INADEQUATE HEAT GENERATION AT THE TIP AND THE EXHAUST HEAT CAN CAUSE DAMAGE TO PLASTIC TRIM PARTS IN THE AREA. USE ONLY AN ELECTRIC SOLDERING GUN WITH 100 WATTS OR MORE OF POWER. BEFORE USING THE SOLDERING GUN, BE SURE TO MELT A SMALL AMOUNT OF ROSIN CORE SOLDER TO THE TIP. THE SOLDER WILL ASSIST IN ACHIEVING BETTER HEAT TRANSFER FROM THE SOLDERING GUN TIP TO THE NEW TERMINAL. The new terminal has pre-applied solder, flux and temperature sensitive paint. The paint provides a visual indication when the terminal has reached the proper temperature to melt the solder on the terminal. When the proper temperature is achieved the temperature paint will liquefy and change color. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11044 Use terminal type A (Figure 2) for all tab locations except on the Focus vehicle line. For the Focus, use type B (Figure 3). NOTE DEPENDING ON THE ORIGINAL TERMINAL LOCATION, AND WHETHER THE TERMINAL IS COVERED BY PILLAR TRIM, WILL DETERMINE WHERE TO LOCATE THE NEW TERMINAL. SOME GRID LINE BUSS-BARS MAY ONLY ALLOW THE PLACEMENT OF THE TERMINAL ABOVE OR BELOW THE ORIGINAL TAB LOCATION DUE TO SPACE LIMITATIONS, BUT FOR MOST VEHICLE APPLICATIONS THE REPLACEMENT TAB LOCATION WILL COVER THE ORIGINAL TAB LOCATION BUT STILL ALLOW THE REPLACEMENT TAB TO ATTACH TO THE BUSS-BAR ON GOOD CONDUCTIVE MATERIAL. 1. Place the replacement terminal over the original tab location making sure the conductive areas of the terminal will be on a good conductive area. Do not place the terminal tab foot on the original location which does not have conductive material (figure 4). 2. Hold the terminal in place with an item such as regular lead pencil at a 90 degree angle from the terminal. (Terminal type B can be held in place with tape.) (Holding at other than a 90 degree angle may allow the terminal to slip when the solder liquefies). 3. Place the soldering gun tip on the top of the terminal but not on the painted areas of the tab. Energize the soldering gun and watch for the painted area of the terminal to liquefy and change color. The paint should liquefy in approximately 25-45 seconds after heating. As soon as the paint color completely changes on either side of the terminal, de-energize the soldering gun and continue to hold the terminal in place with the soldering gun and pencil for an additional thirty (30) seconds. 4. Remove the soldering gun and pencil from the terminal. The terminal should be allowed to cool for another two (2) minutes before the wiring lead is attached to the terminal. 5. Attach the electrical lead connection to this terminal, turn on the rear defroster, and verify operation. Parts Block Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11045 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042405A Repair Grid Lines (Includes 0.7 Hr. Time To Diagnose And Recheck) 042405B Replace Terminal (Includes 0.4 Hr. Time To Diagnose And Recheck) 042405C Repair Grid Lines And 0.8 Hr. Replace Terminal (Includes Time To Diagnose And Recheck) DEALER CODING CONDITION BASIC PART NO. CODE 7042006 28 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions Heated Glass Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11051 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11052 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11053 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11054 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11055 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11056 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11057 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11058 Heated Glass Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11059 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11060 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11061 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11062 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11063 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11064 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Control Module > Component Information > Diagrams > Page 11065 Heated Glass Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Windows; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 11069 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 11070 Heated Glass Element Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Window Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11075 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11076 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11077 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11078 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11079 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11080 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11081 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11082 Power Window Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11083 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11084 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11085 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11086 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11087 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11088 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Diagrams > Page 11089 Power Window Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Windows; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Accessory Delay Relay Power Window Relay: Locations Accessory Delay Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 11094 The accessory delay relay is located in the central junction box, under the dash panel, LH side. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 11095 Power Window Relay: Locations One Touch Down Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 11096 The one touch down relay is located in the central junction box, under the dash panel, LH side. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 11097 Power Window Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams > Page 11102 Heated Glass Element Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the steering column opening cover. NOTE: Position the gear shifter into low or drive 1 position. 3. Remove the headlamp switch. For additional information, refer to Lighting and Horns. 4. Remove the instrument panel finish panel. 1 Remove the panel bolts. 2 Remove the instrument panel finish panel. 5. Disconnect the electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams > Page 11103 6. Remove the rear window defrost switch. ^ Remove the screws. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch Power Window Switch: Diagrams Power Window Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 11108 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 11109 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 11110 Power Window Switch: Diagrams Vent Window Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power window Switch Power Window Switch: Testing and Inspection Power window Switch Left Front Component Testing Procedure (Part 1 Of 2) Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 11113 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 11114 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 11115 Schematic Right Front Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 11116 Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 11117 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 11118 Power Window Switch: Testing and Inspection Rear Window Switch Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 11119 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions Power Window Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11125 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11126 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11127 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11128 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11129 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11130 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11131 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11132 Power Window Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11133 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11134 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11135 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11136 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11137 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11138 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Diagrams > Page 11139 Power Window Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Windows; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service Precautions Front Door Window Motor: Service Precautions CAUTION: Support the window glass to avoid damage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service Precautions > Page 11144 Front Door Window Motor: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOL(S) REMOVAL NOTE: The window regulator and motor are removed as an assembly. 1. Remove the front door trim panel. 2. Remove the front door radio speaker. 3. Remove the front door watershield. 4. Raise and support the front door window glass to the full up position. CAUTION: Support the window glass to avoid damage. 5. Disconnect the power window motor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service Precautions > Page 11145 6. Remove the window glass to regulator nuts. 7. Remove the motor and window regulator assembly. 1 Drill out the rivets. 2 Remove the motor and window regulator assembly. 8. Remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. NOTE: Prior to motor removal, make sure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service Precautions > Page 11146 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. ^ Cycle the door glass to make sure of gear engagement. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service Precautions > Page 11147 Heavy Duty Riveter Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Quarter Window Motor > Component Information > Service and Repair Quarter Window Motor: Service and Repair REMOVAL 1. Remove the quarter trim panel. 2. Unclip the quarter window regulator from the quarter window. 3. Remove the rear quarter glass motor. 1 Disconnect the electrical connector. 2 Remove the nuts and the rear quarter glass motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service Precautions Rear Door Window Motor: Service Precautions CAUTION: Support the window glass to avoid damage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service Precautions > Page 11154 Rear Door Window Motor: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOL(S) REMOVAL NOTE: The window regulator and motor are removed as an assembly. 1. Remove the rear door trim panel. 2. Remove the rear door radio speaker. 3. Remove the rear door watershield. 4. Raise and support the rear door window glass to the full up position. CAUTION: Support the window glass to avoid damage. 5. Disconnect the power window motor electrical connector. 6. Remove the window glass to regulator nuts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service Precautions > Page 11155 7. Remove the motor and window regulator assembly. 1 Drill out the rivets. 2 Remove the motor and window regulator assembly. 8. Remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. NOTE: Prior to motor removal, make sure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. ^ Cycle the door glass to make sure of gear engagement. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service Precautions > Page 11156 Heavy Duty Riveter Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Accessory Delay Relay Power Window Relay: Locations Accessory Delay Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 11161 The accessory delay relay is located in the central junction box, under the dash panel, LH side. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 11162 Power Window Relay: Locations One Touch Down Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Accessory Delay Relay > Page 11163 The one touch down relay is located in the central junction box, under the dash panel, LH side. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Page 11164 Power Window Relay: Testing and Inspection Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Power Window Switch Power Window Switch: Diagrams Power Window Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 11169 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 11170 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Power Window Switch > Page 11171 Power Window Switch: Diagrams Vent Window Switch Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Power window Switch Power Window Switch: Testing and Inspection Power window Switch Left Front Component Testing Procedure (Part 1 Of 2) Component Testing Procedure (Part 2 Of 2) Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 11174 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 11175 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 11176 Schematic Right Front Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 11177 Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 11178 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 11179 Power Window Switch: Testing and Inspection Rear Window Switch Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Power window Switch > Page 11180 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair Front Door Window Glass: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove the front door radio speaker. 3. Remove the front door watershield. 4. Lower the window glass to access the two window glass to regulator nuts. 5. Remove the inside glass weatherstrip. 6. Remove the front door rear glass channel bolt and position the channel aside. 7. Remove the window glass to regulator nuts. 8. Remove the front door window glass. NOTE: Slide the glass through the outboard side of the door. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair > Page 11185 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair REMOVAL 1. Disconnect the rear window defrost grid electrical connector. 2. Remove the liftgate trim panels. 3. Disconnect the liftgate window glass support. 1 Remove the E-clip. 2 Remove the pin. 3 Disconnect the support. NOTE: Have an assistant hold the liftgate window glass. 4. Remove the liftgate window glass. 1 Remove the four bolts (two each side). 2 Remove the liftgate window glass. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 11189 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed Quarter Window Glass: Service and Repair Fixed REMOVAL 1. Remove the quarter trim panel. 2. Remove the rear quarter window glass. ^ On the RH quarter window glass, disconnect the antenna cable in-line connector. 1 Remove the nuts. 2 Push the rear quarter window glass outward to release the foam butyl seal. CAUTION: Have an assistant hold the rear quarter window glass. 3. Remove the excess foam butyl from the window opening. INSTALLATION 1. Apply 8 mm Foam Butyl or equivalent meeting Ford specification WSB-M2G234-C to the rear quarter window glass frame. ^ Start at the bottom middle and work around the frame. NOTE: When applying foam butyl, leave a slight overlap at the bottom to allow for drainage. 2. Install the rear quarter window glass. 1 Position the rear quarter window glass. 2 Install quarter window glass nuts. ^ On the RH quarter window glass, connect the antenna cable in-line connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed > Page 11194 NOTE: Loosely install all the nuts before tightening. 3. Install the quarter trim panel. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed > Page 11195 Quarter Window Glass: Service and Repair Frame, Rear Quarter, Vented REMOVAL 1. Remove the vented rear quarter window glass. For additional information, refer to Window Glass-Rear Quarter, Vented. 2. Remove the quarter window glass frame. 1 Remove the 10 nuts. 2 Remove the quarter window glass frame. 3. Clean the excess foam butyl from the window opening. INSTALLATION 1. Apply 8 mm Foam Butyl or equivalent meeting Ford specification WSB-M2G234-C to the rear quarter window glass frame. ^ Start at the bottom middle and work around the frame. NOTE: When applying foam butyl, leave a slight overlap at the bottom to allow for drainage. 2. Install the rear quarter window glass frame. 1 Position the rear quarter window glass frame. 2 Install the 10 nuts. NOTE: Loosely install all the nuts before tightening. 3. Install the rear quarter window glass. For additional information, refer to Window Glass-Rear Quarter, Vented. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Fixed > Page 11196 Quarter Window Glass: Service and Repair Quarter REMOVAL 1. Remove the quarter trim panel. 2. Remove the C-pillar trim panel. 3. If equipped, on the RH quarter window glass, remove the portable cellular phone antenna base. For additional information, refer to Cellular Phone. 4. Remove the D-pillar trim panel. 5. Unclip the quarter window regulator from the quarter window. ^ If necessary, remove the quarter window regulator bracket bolt. 6. Remove the quarter window glass. ^ On the RH quarter window glass, disconnect the antenna cable in-line connector. 1 Remove the nuts. 2 Remove the quarter window glass. ^ If required, remove the quarter window glass hinge bolts. CAUTION: Have an assistant hold the rear quarter window glass. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair REMOVAL 1. Remove the rear door trim panel. 2. Remove the rear door radio speaker. 3. Remove the rear door watershield. 4. Remove the inside glass weatherstrip. 5. Remove the rear door glass channel lower bolt. 6. Remove the rear door fixed vent screw. 7. Lift the rear door rear glass and channel away from the door glass. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Page 11200 8. Remove the window glass to regulator nuts. 9. Remove the rear door glass. NOTE: Slide the glass through the outboard side of the door. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Specifications Front Door Window Regulator: Specifications Window Glass To Regulator Nuts 10-14 Nm Window Regulator Nuts 10-14 Nm Quarter Window Regulator Bracket Bolt 2 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Specifications > Page 11205 Front Door Window Regulator: Service Precautions CAUTION: Support the window glass to avoid damage. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Specifications > Page 11206 Front Door Window Regulator: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOL(S) REMOVAL NOTE: The window regulator and motor are removed as an assembly. 1. Remove the front door trim panel. 2. Remove the front door radio speaker. 3. Remove the front door watershield. 4. Raise and support the front door window glass to the full up position. CAUTION: Support the window glass to avoid damage. 5. Disconnect the power window motor electrical connector. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Specifications > Page 11207 6. Remove the window glass to regulator nuts. 7. Remove the motor and window regulator assembly. 1 Drill out the rivets. 2 Remove the motor and window regulator assembly. 8. Remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. NOTE: Prior to motor removal, make sure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Specifications > Page 11208 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. ^ Cycle the door glass to make sure of gear engagement. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Specifications > Page 11209 Heavy Duty Riveter Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications Rear Door Window Regulator: Specifications Window Glass To Regulator Nuts 10-14 Nm Window Regulator Nuts 10-14 Nm Quarter Window Regulator Bracket Bolt 2 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications > Page 11213 Rear Door Window Regulator: Service and Repair Heavy Duty Riverter SPECIAL SERVICE TOOL(S) REMOVAL NOTE: The window regulator and motor are removed as an assembly. 1. Remove the rear door trim panel. 2. Remove the rear door radio speaker. 3. Remove the rear door watershield. 4. Raise and support the rear door window glass to the full up position. CAUTION: Support the window glass to avoid damage. 5. Disconnect the power window motor electrical connector. 6. Remove the window glass to regulator nuts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications > Page 11214 7. Remove the motor and window regulator assembly. 1 Drill out the rivets. 2 Remove the motor and window regulator assembly. 8. Remove the power window motor. 1 Remove the bolts. 2 Remove the power window motor. NOTE: Prior to motor removal, make sure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION 1. To install, reverse the removal procedure. ^ Use Heavy Duty Riveter to install the new rivets. ^ Cycle the door glass to make sure of gear engagement. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications > Page 11215 Heavy Duty Riveter Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel Window Track: Customer Interest Body - Front Window(s) Pop/Thump Noise at End of Travel Article No. 04-5-7 03/22/04 BODY - FRONT WINDOW(S) - POP/THUMP NOISE AT END OF WINDOW TRAVEL AND/OR DRIVER'S WINDOW BOUNCE BACK AND REVERSE TO MID-POSITION FORD: 1997-2003 F-150 1997-2004 EXPEDITION LINCOLN: 1998-2004 NAVIGATOR ISSUE Some 1997-2004 Expedition, 1998-2004 Navigator built through 04/01/2004 and 1997-2003 F-150, may exhibit a pop/thump noise at the end of window travel when either front window is rolled up. Some 2003-2004 Navigator vehicles may also exhibit a driver's door glass bounce back and reverse to a mid-position. The condition may exist when the vehicle is stationary or traveling at low speeds, however the condition will become more pronounced when traveling at higher speeds. This may be due to the window glass being too far outboard and catching on the glass run before seating. ACTION To service, adjust the window's travel path inward, by bending the flange on which the glass run is mounted. Refer to the Service Procedure below. SERVICE PROCEDURE 1. Remove inner door panel, refer to Workshop Manual Section 501-11. 2. Remove exterior mirror, refer to Workshop Manual Section 501-09. 3. Torque door glass retainers for regulator to door, window glass to regulator, and both front and rear window runs to 11 N.m (8 lb-ft). 4. Lower door glass to position it out of the way. 5. Remove inner and outer belt molding. 6. Position aside front window run. a. Remove retainer. b. Position outside of work area. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel > Page 11224 7. Bend flange inboard about 10 degrees, using a pair of sheet metal clamp locking pliers (Figure 1). Starting at the bend at the top of the sail plate, and working down approximately 25.40 cm (10") (Figure 2). NOTE TAKE CARE NOT TO OVER BEND FLANGE, THIS MAY INDUCE WIND NOISE. 8. Reposition front window run. a. Install retainer. b. Torque retainer to 11 N.m (8 lb-ft). 9. Install inner and outer belt molding. 10. Install exterior mirror, refer to Workshop Manual Section 501-09. 11. Install inner door panel, refer to Workshop Manual Section 501-11. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel > Page 11225 12. 2003-2004 Navigator vehicles, re-initialize drivers window according to Workshop Manual Section 501-11. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7820125 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel Window Track: All Technical Service Bulletins Body - Front Window(s) Pop/Thump Noise at End of Travel Article No. 04-5-7 03/22/04 BODY - FRONT WINDOW(S) - POP/THUMP NOISE AT END OF WINDOW TRAVEL AND/OR DRIVER'S WINDOW BOUNCE BACK AND REVERSE TO MID-POSITION FORD: 1997-2003 F-150 1997-2004 EXPEDITION LINCOLN: 1998-2004 NAVIGATOR ISSUE Some 1997-2004 Expedition, 1998-2004 Navigator built through 04/01/2004 and 1997-2003 F-150, may exhibit a pop/thump noise at the end of window travel when either front window is rolled up. Some 2003-2004 Navigator vehicles may also exhibit a driver's door glass bounce back and reverse to a mid-position. The condition may exist when the vehicle is stationary or traveling at low speeds, however the condition will become more pronounced when traveling at higher speeds. This may be due to the window glass being too far outboard and catching on the glass run before seating. ACTION To service, adjust the window's travel path inward, by bending the flange on which the glass run is mounted. Refer to the Service Procedure below. SERVICE PROCEDURE 1. Remove inner door panel, refer to Workshop Manual Section 501-11. 2. Remove exterior mirror, refer to Workshop Manual Section 501-09. 3. Torque door glass retainers for regulator to door, window glass to regulator, and both front and rear window runs to 11 N.m (8 lb-ft). 4. Lower door glass to position it out of the way. 5. Remove inner and outer belt molding. 6. Position aside front window run. a. Remove retainer. b. Position outside of work area. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel > Page 11231 7. Bend flange inboard about 10 degrees, using a pair of sheet metal clamp locking pliers (Figure 1). Starting at the bend at the top of the sail plate, and working down approximately 25.40 cm (10") (Figure 2). NOTE TAKE CARE NOT TO OVER BEND FLANGE, THIS MAY INDUCE WIND NOISE. 8. Reposition front window run. a. Install retainer. b. Torque retainer to 11 N.m (8 lb-ft). 9. Install inner and outer belt molding. 10. Install exterior mirror, refer to Workshop Manual Section 501-09. 11. Install inner door panel, refer to Workshop Manual Section 501-11. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Track: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel > Page 11232 12. 2003-2004 Navigator vehicles, re-initialize drivers window according to Workshop Manual Section 501-11. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7820125 42 Disclaimer Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Technician Safety Information Windshield: Technician Safety Information WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING EYES OR CUTTING HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING GLASS FROM THE VEHICLE. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Technician Safety Information > Page 11237 Windshield: Vehicle Damage Warnings CAUTION: ^ Care must be taken to avoid scratching the pinchweld. ^ After replacing the urethane installed glass, the vehicle should not be driven until the Urethane Sealant has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (decreasing at higher temperatures and lower humidities). Inadequate curing of the Urethane Sealant may adversely affect the strength of the Urethane Sealant bond. ^ Wipe off the Urethane Glass Prep immediately after each application because it flask dries. ^ If a vehicle is to be driven within 24 hours of urethane sealant application, Urethane sealant Essex U-216 meeting Ford specification WSB-M2G316-B must be used due to its one hour cure time. ^ Open the windows to prevent the windshield glass from being pushed out by air pressure if a door is closed. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11238 Windshield: Service and Repair SPECIAL SERVICE TOOL(S) REMOVAL WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING EYES OR CUTTING HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING GLASS FROM THE VEHICLE. 1. Remove the cowl grille. See: Body and Frame/Cabin Ventilation Grille 2. Remove the LH and RH A-pillar assist handles. 1 Remove the cover and the screws 2 Remove the assist handles. 3. Remove the windshield side garnish mouldings. 4. Remove the overhead console. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11239 5. Remove the interior rear view mirror. For additional information, refer to Mirrors. 6. Position the two sun visors into the side window position and remove the two inside screws. 7. Position the two sun visors into the stored position. 8. Remove the two sun visors. 1 Remove the four screws 2 Remove the two sun visor and visor arm clips ^ If equipped, disconnect the electrical connectors. 9. Lower the front portion of the headliner. 10. Remove the upper windshield weatherstrip. 11. Remove the LH and RH windshield mouldings. 12. Mark the outside of the windshield glass with a wax pencil to avoid damaging the glass stops when cutting the urethane. 13. Using a soft brush or vacuum, remove any dirt and foreign material from the pinch weld. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11240 14. Using the special tool, cut the Urethane Sealant from the windshield glass. ^ Insert the blade into the urethane at the top middle and work toward the bottom corners. CAUTION: Care must be taken to avoid scratching the pinchweld. NOTE: Lubricate the Urethane Sealant with water to aid the special tool while cutting. 15. Using the special tool, distance the windshield from the body. 16. Using the special tool, cut the remaining urethane sealant and remove the windshield glass. NOTE: Removing the windshield glass requires more than one technician. 17. Using a soft brush or vacuum, remove any dirt and foreign material from the pinch weld. INSTALLATION CAUTION: After replacing the urethane installed glass, the vehicle should not be driven until the Urethane Sealant has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (decreasing at higher temperatures and lower humidities). Inadequate curing of the Urethane Sealant may adversely affect the strength of the Urethane Sealant bond. 1. Dry-fit the windshield glass by centering it side to side and by adjusting the setting blocks (if equipped) to get the correct position of the part top to bottom. Make the alignment marks with tape or non-staining grease pencil on both the glass and the vehicle body. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11241 2. Trim the remaining Urethane Sealant on the pinch weld to within specification. ^ The old urethane surface should be smooth and free of cuts and contamination. CAUTION: Care must be taken to avoid scratching the pinchweld. 3. Use the wool applicator to apply Urethane Metal Primer Essex U-413, meeting Ford specification WSB-M2G314-B to any exposed metal on the pinch weld. Allow six to ten minutes to dry. 4. Apply 8 mm Foam Butyl or equivalent meeting Ford specification WSB-M2G234-C to the pinch weld. 5. If reinstalling the original windshield, remove excess Urethane Sealant from the windshield glass. 6. If installing a new windshield glass, clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area is clean. 7. Apply Urethane Glass Prep Essex U-401 or equivalent meeting Ford specification WSB-M2G314-B twice around the glass surface to be prepped. CAUTION: Wipe off the Urethane Glass Prep immediately after each application because it flask dries. NOTE: Apply with deliberate strokes, making sure not to overlap applied area. 8. Apply Urethane Glass Primer Essex U-402 meeting Ford specification WSB-M5B280-C to the same area that was in the previous step. Allow five minutes to dry. 9. Cut the urethane applicator tip to specification. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11242 10. Apply a bead of Urethane Sealant Essex 400 HV or Essex U-216 meeting Ford specification WSB-M2G316-B to the pinch weld just outside the foam butyl dam. CAUTION: If a vehicle is to be driven within 24 hours of urethane sealant application, Urethane sealant Essex U-216 meeting Ford specification WSB-M2G316-B must be used due to its one hour cure time. 11. Install the interior rear view mirror. For additional information, refer to Mirrors. 12. Using the alignment marks, install the windshield glass. CAUTION: Open the windows to prevent the windshield glass from being pushed out by air pressure if a door is closed. 13. Install the upper windshield weatherstrip. 14. Paddle the excess Urethane Sealant from the two sides of the windshield glass. NOTE: Use one continuous stroke when removing the excess Urethane Sealant. 15. If necessary, remove excess Urethane Sealant from the outside surface of the windshield glass. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11243 16. Install the LH and RH windshield mouldings. 17. Install the headliner. 18. Install the overhead console. 19. Install the windshield side garnish mouldings. 20. Install the LH and RH sun visors. 1 Position the sun visors. 2 Install the four screws. ^ If equipped, connect the electrical connectors. 21. Position the LH and RH sun visors to the side window position and install the sun visor inside screws. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Page 11244 22. Install the LH and RH A-pillar assist handles. 1 Position the two A-pillar assist handles. 2 Install the four screws and covers. 23. Install the cowl grille. See: Body and Frame/Cabin Ventilation Grille Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Tools and Equipment > Recommended Tools and Equipment Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Tools and Equipment > Recommended Tools and Equipment > Page 11247 Windshield: Tools and Equipment Recommended Sealers and Adhesives Recommended Sealers and Adhesives 8 mm Foam Butyl ................................................................................................................................ ........................................................ WSB-M2G234-C Urethane Glass Prep Essex U-401 ........................................................................................................................................................... WSB-M2G314-B Urethane Metal Primer Essex U-413 .......................................................................................................................................................... WSB-M2G234-C Urethane Sealant Essex 400HV .............................................................................. .................................................................................... WSB-M2G316-B Urethane Sealant Essex U-216 ................................................................................................................................................... ................. WSB-M2G316-B Urethane Glass Primer Essex U-402 ........................................................................................................................................................... WSB-MSB280-C Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11254 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11255 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11256 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11257 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11258 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11259 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11260 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11261 Windshield Washer Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11262 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11263 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11264 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11265 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11266 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11267 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Rear Washer Pump Relay Windshield Washer Relay: Locations Rear Washer Pump Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Rear Washer Pump Relay > Page 11272 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Rear Washer Pump Relay > Page 11273 Windshield Washer Relay: Locations Washer Pump Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Rear Washer Pump Relay > Page 11274 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 11275 Windshield Washer Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions Wiper Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11280 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11281 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11282 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11283 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11284 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11285 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11286 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11287 Wiper Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11288 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11289 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11290 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11291 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11292 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11293 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 11294 Wiper Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Wiper and Washer Systems; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay Wiper Relay: Locations Wiper High/Low Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 11299 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 11300 Wiper Relay: Locations Wiper Run/Park Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 11301 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 11302 Wiper Relay: Locations Rear Wiper Up Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 11303 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 11304 Wiper Relay: Locations Rear Wiper Down Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 11305 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Wiper High/Low Relay Wiper Relay: Testing and Inspection Wiper High/Low Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Wiper High/Low Relay > Page 11308 Wiper Relay: Testing and Inspection Wiper Run/Park Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Wiper High/Low Relay > Page 11309 Wiper Relay: Testing and Inspection Rear Wiper Up Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Wiper High/Low Relay > Page 11310 Wiper Relay: Testing and Inspection Rear Wiper Down Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Windshield Washer Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 11315 Windshield Washer Switch: Description and Operation The steering column switches consist of the: ^ multifunction switch, which controls the: ^ turn signal. ^ hazard flasher. ^ windshield wiper/washer. ^ rear wiper/washer. ^ headlamp dimmer/flash-to-pass. ^ ignition switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection Windshield Washer Switch: Testing and Inspection Initial Inspection 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11318 Windshield Washer Switch: Testing and Inspection Generic Electronic Module (GEM) DTC Index B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11319 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11320 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11321 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11322 P1836-P1891 Part 5 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11323 Windshield Washer Switch: Testing and Inspection GEM Active Command Index Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11324 Windshield Washer Switch: Testing and Inspection Generic Electronic Module (GEM) PID Index Part 1 of 3 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11325 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11326 Windshield Washer Switch: Testing and Inspection Initial Inspection 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Generic Electronic Module (GEM) DTC Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11327 B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11328 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11329 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11330 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11331 P1836-P1891 Part 5 of 5 GEM Active Command Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11332 Part 1 of 2 Part 2 of 2 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11333 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11334 Part 3 of 3 Component Tests Multifunction Switch Tests Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11335 Component Testing Procedure Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11336 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11337 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11338 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11339 Test A: No Communication With the Module-GEM Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11340 Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11341 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11342 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11343 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11344 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11345 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 11346 Windshield Washer Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Note: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 11347 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the multi function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the multi function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Wiper Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 11351 Wiper Switch: Description and Operation The steering column switches consist of the: ^ multifunction switch, which controls the: ^ turn signal. ^ hazard flasher. ^ windshield wiper/washer. ^ rear wiper/washer. ^ headlamp dimmer/flash-to-pass. ^ ignition switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection Wiper Switch: Testing and Inspection Initial Inspection 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11354 Wiper Switch: Testing and Inspection Generic Electronic Module (GEM) DTC Index B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11355 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11356 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11357 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11358 P1836-P1891 Part 5 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11359 Wiper Switch: Testing and Inspection Component Tests Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11360 Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11361 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11362 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11363 Wiper Switch: Testing and Inspection GEM Active Command Index Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11364 Wiper Switch: Testing and Inspection Initial Inspection 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Generic Electronic Module (GEM) DTC Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11365 B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11366 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11367 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11368 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11369 P1836-P1891 Part 5 of 5 Component Tests Multifunction Switch Tests Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11370 Component Testing Procedure Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11371 Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11372 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11373 Schematic GEM Active Command Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11374 Part 1 of 2 Part 2 of 2 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11375 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11376 Part 3 of 3 Test A: No Communication With the Module-GEM Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11377 Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11378 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11379 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11380 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11381 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11382 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 11383 Wiper Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Note: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 11384 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the multi function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the multi function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11389 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11390 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11391 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11392 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11393 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11394 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11395 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11396 Windshield Washer Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11397 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11398 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11399 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11400 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11401 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11402 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service Precautions Windshield Washer Pump: Service Precautions CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service Precautions > Page 11406 Windshield Washer Pump: Service and Repair REMOVAL 1. Disconnect the jack handle from the windshield washer reservoir. 2. Disconnect the electrical connectors. 3. Remove the windshield washer reservoir screws. 4. Disconnect the windshield washer hoses. NOTE: Windshield washer fluid should be collected in a container after the windshield washer hoses are disconnected. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service Precautions > Page 11407 5. Remove the windshield washer reservoir. 6. Remove the windshield washer pump. INSTALLATION 1. To install, reverse the removal procedure. ^ Fill the windshield washer reservoir with Ultra-Clear Windshield Washer Concentrate C9AZ-19550-AC or BC or equivalent meeting Ford specification ESR-M17P5-A. CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Rear Washer Pump Relay Windshield Washer Relay: Locations Rear Washer Pump Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Rear Washer Pump Relay > Page 11412 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Rear Washer Pump Relay > Page 11413 Windshield Washer Relay: Locations Washer Pump Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Rear Washer Pump Relay > Page 11414 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 11415 Windshield Washer Relay: Testing and Inspection Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications Windshield Washer Reservoir: Specifications Windshield Washer Reservoir Screws 4.6-5.4 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 11419 Windshield Washer Reservoir: Service and Repair REMOVAL 1. Disconnect the jack handle from the windshield washer reservoir. 2. Disconnect the electrical connectors. 3. Remove the windshield washer reservoir screws. 4. Disconnect the windshield washer hoses. NOTE: Windshield washer fluid should be collected in a container after the windshield washer hoses are disconnected. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 11420 5. Remove the windshield washer reservoir. 6. Remove the windshield washer pump. INSTALLATION 1. To install, reverse the removal procedure. ^ Fill the windshield washer reservoir with Ultra-Clear Windshield Washer Concentrate C9AZ-19550-AC or BC or equivalent meeting Ford specification ESR-M17P5-A. CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams Windshield Washer Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 11424 Windshield Washer Switch: Description and Operation The steering column switches consist of the: ^ multifunction switch, which controls the: ^ turn signal. ^ hazard flasher. ^ windshield wiper/washer. ^ rear wiper/washer. ^ headlamp dimmer/flash-to-pass. ^ ignition switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection Windshield Washer Switch: Testing and Inspection Initial Inspection 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11427 Windshield Washer Switch: Testing and Inspection Generic Electronic Module (GEM) DTC Index B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11428 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11429 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11430 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11431 P1836-P1891 Part 5 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11432 Windshield Washer Switch: Testing and Inspection GEM Active Command Index Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11433 Windshield Washer Switch: Testing and Inspection Generic Electronic Module (GEM) PID Index Part 1 of 3 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11434 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11435 Windshield Washer Switch: Testing and Inspection Initial Inspection 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Generic Electronic Module (GEM) DTC Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11436 B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11437 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11438 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11439 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11440 P1836-P1891 Part 5 of 5 GEM Active Command Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11441 Part 1 of 2 Part 2 of 2 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11442 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11443 Part 3 of 3 Component Tests Multifunction Switch Tests Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11444 Component Testing Procedure Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11445 Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11446 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11447 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11448 Test A: No Communication With the Module-GEM Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11449 Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11450 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11451 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11452 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11453 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11454 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 11455 Windshield Washer Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Note: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 11456 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the multi function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the multi function switch. Installation 1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications Wiper Arm: Specifications Windshield Wiper Pivot Arm Nuts 30-40 Nm Rear Window Wiper Pivot Arm Nut 13-17 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 11460 Wiper Arm: Service Precautions CAUTION: Use a shop towel or similar device to protect the vehicle finish when performing the procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 11461 Wiper Arm: Adjustments 1. Cycle and park the windshield wipers. 2. Verify the distance between the center of the (A) RH windshield wiper blade and the (C) bottom of the windshield glass is within specification. 3. Verify the distance between the center of the (B) LH windshield wiper blade and the (C) bottom of the windshield glass is within specification. 4. If the distance is not within specification, remove the windshield wiper pivot arm and reposition to specification. 1 Remove the pivot arm nut cover. 2 Remove the nut. 3 Remove and reposition the windshield wiper pivot arm. 5. Tighten the windshield wiper pivot arm nuts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Windshield Wiper Pivot Arm Wiper Arm: Service and Repair Windshield Wiper Pivot Arm REMOVAL 1. Remove the windshield wiper pivot arm. 1 Remove the pivot arm nut cover. 2 Remove the nut. 3 Remove the windshield wiper pivot arm. INSTALLATION 1. To install, reverse the removal procedure. ^ Adjust the windshield wiper pivot arms. For additional information, refer to Wiper Blade and Pivot Arm Adjustment-Windshield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Windshield Wiper Pivot Arm > Page 11464 Wiper Arm: Service and Repair Rear Pivot Arm REMOVAL 1. Remove rear pivot arm. 1 Lift the pivot arm nut cover. 2 Remove the nut. 3 Remove the pivot arm. CAUTION: Use a shop towel or similar device to protect the vehicle finish when performing the procedure. INSTALLATION 1. Turn the rear wiper switch on and allow the motor to operate for at least one cycle. Turn the rear wiper switch to off. NOTE: This step ensures that the wiper motor is in the park position. 2. Position the wiper blade outside the wiper arm stop. 3. Install the wiper pivot arm onto the wiper motor. ^ Tighten the retaining nut. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Windshield Wiper Pivot Arm > Page 11465 4. Cycle the wiper motor one time to allow the wiper arm to park on the wiper arm stop. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Specifications Wiper Blade: Specifications Clearance to Bottom of Windshield -RH Blade 65-93 mm Clearance to Bottom of Windshield -LH Blade 45-75 mm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Specifications > Page 11469 Wiper Blade: Adjustments 1. Cycle and park the windshield wipers. 2. Verify the distance between the center of the (A) RH windshield wiper blade and the (C) bottom of the windshield glass is within specification. 3. Verify the distance between the center of the (B) LH windshield wiper blade and the (C) bottom of the windshield glass is within specification. 4. If the distance is not within specification, remove the windshield wiper pivot arm and reposition to specification. 1 Remove the pivot arm nut cover. 2 Remove the nut. 3 Remove and reposition the windshield wiper pivot arm. 5. Tighten the windshield wiper pivot arm nuts. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions Wiper Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams ^ System Diagrams ^ Grounds Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11474 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11475 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11476 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11477 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Component Identification Information Component Identification Information consists of (1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces). The A-Z Component List helps the user find where the various items depicted on the diagram can physically be found on the vehicle. A brief written description of the location is given. See: Locations/Component Locations/A-Z Component List The Component Location Views show the components and their connecting wires as they can be found on the vehicle. See: Locations/Component Locations/Component Location Views The Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number. See: Diagrams/Connector Views Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11478 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11479 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11480 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11481 Wiper Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. ^ Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. ^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. ^ Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. ^ Use electrical test procedures to find the specific cause of the symptoms. ^ The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. ^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. ^ Repair or replace the inoperative component. Step 6. Verify the repair. ^ Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11482 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11483 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: ^ Motors: disconnect motor connector (Connector C4). ^ Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). ^ If the Test Lamp is off, the short is in the disconnected component. ^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11484 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11485 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11486 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11487 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Page 11488 Wiper Control Module: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Wiper and Washer Systems; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > NHTSA01V258000 > Aug > 01 > Recall 01V258000: Wiper Motor Gear Case Cover Wiper Motor: Recalls Recall 01V258000: Wiper Motor Gear Case Cover Vehicle Description: Passenger cars, sport utility vehicles, and light and medium duty pickup trucks. A switch located in the plastic cover of the wiper motor gear case could malfunction and overheat, potentially resulting in loss of intermittent wiper function, loss of wiper park function, complete loss of wiper function, smoke or, potentially, ignition of the plastic cover material. Switch malfunction is most likely to occur when the intermittent setting of the wipers is being used, or when snow or ice obstructs the blades from returning to the "parked" position at the bottom of the windshield. These vehicles were built at the following assembly plants: plant from 2/11/00 through 7/31/00; Chicago plant from 2/14/00 through 8/4/00; Kansas City plant from 2/26/00 to 9/4/00; Kentucky Truck plant from 2/18/00 to 8/31/00; Michigan Truck plant from 2/23/00 through 8/3/00; Norfolk plant from 2/21/00 through 7/27/00; Wayne Stamping and Assembly plant from 2/25/00 through 8/15/00; and Wixom plant from 2/15/00 through 8/8/00. Loss of visibility while driving increases the risk of a crash. Dealers will inspect the date code on the wiper motor. Motors built with the suspect time frame will have the wiper motor gear case cover replaced. Owner notification mailing is expected to begin during September 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-866-436-7332. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover Technical Service Bulletin # 01S24 Date: 010801 Recall - Defective Wiper Motor Switch/Gear Cover SAFETY RECALL 01S24 Certain 2000 and 2001 Model Year Cars and Trucks -- Wiper Motor Gear Cover Replacement Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11501 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer on-line Involved Unit Listings available on QCDealer.com. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11502 ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Rental cars are not authorized for this program. Attachment II - Labor and Parts Information Labor Allowances PARTS REQUIREMENTS FOR ALL INVOLVED VEHICLES EXCEPT FOCUS Parts Ordering Information Parts will be seed stocked for this recall the week following the publication of this bulletin. Stock orders for initial quantities will be 18 to 72 pieces, based on dealer size. Order additional quantities of wiper motor covers after utilization of seed stock, through normal order processing channels as noted. PARTS REQUIREMENTS FOR FOCUS Parts Ordering Information Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11503 Parts will be seed stocked for this recall beginning September 14. Stock orders for initial quantities will be 2 to 10 pieces, based on dealer size. Order additional quantities of wiper motor covers after utilization of seed stock, through normal order processing channels as noted. ORDER INFORMATION DOR/COR number 50253 identifies parts ordered for this campaign. DEALER PRICE For latest prices, refer to DOES II or your updated price book. EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11504 Table of Contents Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11505 Overview I. Pre-Repair Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11506 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11507 II. Determine If Wiper Motor Gear Cover Must Be Replaced F-150, Expedition, Navigator, Continental Taurus, Sable and Focus Excursion, F-250 Through F-750 and Town Car Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11508 III. Wiper Motor Gear Cover Replacement Remove Wiper Motor Gear Cover Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11509 Remove Sealant Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11510 Inspect Motor Electrical Connector Clips Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11511 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11512 Prepare Replacement Cover Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11513 Install Replacement Cover Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11514 IV. Verify Wiper Motor Operation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11515 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11516 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > NHTSA01V258000 > Aug > 01 > Recall 01V258000: Wiper Motor Gear Case Cover Wiper Motor: All Technical Service Bulletins Recall 01V258000: Wiper Motor Gear Case Cover Vehicle Description: Passenger cars, sport utility vehicles, and light and medium duty pickup trucks. A switch located in the plastic cover of the wiper motor gear case could malfunction and overheat, potentially resulting in loss of intermittent wiper function, loss of wiper park function, complete loss of wiper function, smoke or, potentially, ignition of the plastic cover material. Switch malfunction is most likely to occur when the intermittent setting of the wipers is being used, or when snow or ice obstructs the blades from returning to the "parked" position at the bottom of the windshield. These vehicles were built at the following assembly plants: plant from 2/11/00 through 7/31/00; Chicago plant from 2/14/00 through 8/4/00; Kansas City plant from 2/26/00 to 9/4/00; Kentucky Truck plant from 2/18/00 to 8/31/00; Michigan Truck plant from 2/23/00 through 8/3/00; Norfolk plant from 2/21/00 through 7/27/00; Wayne Stamping and Assembly plant from 2/25/00 through 8/15/00; and Wixom plant from 2/15/00 through 8/8/00. Loss of visibility while driving increases the risk of a crash. Dealers will inspect the date code on the wiper motor. Motors built with the suspect time frame will have the wiper motor gear case cover replaced. Owner notification mailing is expected to begin during September 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-866-436-7332. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover Technical Service Bulletin # 01S24 Date: 010801 Recall - Defective Wiper Motor Switch/Gear Cover SAFETY RECALL 01S24 Certain 2000 and 2001 Model Year Cars and Trucks -- Wiper Motor Gear Cover Replacement Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11526 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer on-line Involved Unit Listings available on QCDealer.com. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11527 ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer). Refer to ACESII manual for refund information. RENTAL CARS Rental cars are not authorized for this program. Attachment II - Labor and Parts Information Labor Allowances PARTS REQUIREMENTS FOR ALL INVOLVED VEHICLES EXCEPT FOCUS Parts Ordering Information Parts will be seed stocked for this recall the week following the publication of this bulletin. Stock orders for initial quantities will be 18 to 72 pieces, based on dealer size. Order additional quantities of wiper motor covers after utilization of seed stock, through normal order processing channels as noted. PARTS REQUIREMENTS FOR FOCUS Parts Ordering Information Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11528 Parts will be seed stocked for this recall beginning September 14. Stock orders for initial quantities will be 2 to 10 pieces, based on dealer size. Order additional quantities of wiper motor covers after utilization of seed stock, through normal order processing channels as noted. ORDER INFORMATION DOR/COR number 50253 identifies parts ordered for this campaign. DEALER PRICE For latest prices, refer to DOES II or your updated price book. EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11529 Table of Contents Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11530 Overview I. Pre-Repair Inspection Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11531 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11532 II. Determine If Wiper Motor Gear Cover Must Be Replaced F-150, Expedition, Navigator, Continental Taurus, Sable and Focus Excursion, F-250 Through F-750 and Town Car Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11533 III. Wiper Motor Gear Cover Replacement Remove Wiper Motor Gear Cover Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11534 Remove Sealant Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11535 Inspect Motor Electrical Connector Clips Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11536 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11537 Prepare Replacement Cover Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11538 Install Replacement Cover Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11539 IV. Verify Wiper Motor Operation Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11540 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 01S24 > Aug > 01 > Recall - Defective Wiper Motor Switch/Gear Cover > Page 11541 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Page 11542 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Page 11543 Wiper Motor: Testing and Inspection CAUTION: Do not handle the wiper motor abusively when diagnosing the wiper operations. Failure to follow this caution may result in damage to the motor magnets and will make the wiper motor inoperative. Rough handling of new replacement wiper motors may also damage the motor magnets. Use Alternator, Regulator, Battery and Starter Tester (ARBST) to test the wiper motor on the vehicle. To test the wiper motor, disconnect the windshield wiper mounting arm and pivot shaft from the windshield wiper motor; refer to Pivot Arm-Front or Pivot Arm-Rear. Disconnect the wiper motor. Connect the (1) green lead from (2) Alternator, Regulator, Battery and Starter Tester (ARBST) to the battery negative (-) post. Connect the (3) red lead from ARBST to the wiper motor (4) common brush terminal (terminal 3). Test the low speed mode by connecting a (5) cable from the battery positive (+) post to the (6) low speed brush terminal (terminal 4) and measure the current draw. If the current draw is greater than 3.5 amperes, replace the windshield wiper motor. Test the high speed mode by connecting a cable from the battery positive (+) post to the (7) high speed brush terminal (terminal 5) and measure the current draw. If the current draw is greater than 5.5 amperes, replace the wiper motor. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper Wiper Motor: Service and Repair Windshield Wiper REMOVAL 1. Remove the mounting arm and pivot shaft. For additional information, refer to Mounting Arm and Pivot Shaft-Windshield Wiper. 2. Disconnect the windshield wiper linkage. 1 Remove the bolt. 2 Disconnect the windshield wiper linkage. 3. Remove the windshield wiper motor. 1 Remove the bolts. 2 Remove the windshield wiper motor. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper > Page 11546 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper > Page 11547 Wiper Motor: Service and Repair Rear Wiper REMOVAL 1. Remove the rear pivot arm. For additional information, refer to Pivot Arm-Rear. 2. Remove the upper liftgate trim panel. 3. Remove the liftgate assist strap. 1 Remove the screws. 2 Remove the liftgate assist strap. 4. Remove the lower liftgate trim panel. 5. Remove the liftgate watershield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Windshield Wiper > Page 11548 6. Remove the rear window wiper motor. 1 Disconnect the electrical connector. 2 Remove the three screws. 3 Remove the rear window wiper motor. INSTALLATION 1. To install, reverse the removal procedure. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications Wiper Motor Linkage: Specifications Windshield Wiper Mounting Arm And Pivot Shaft Bolts 7-9 Nm Windshield Wiper Linkage Bolt 14.8-20.2 Nm Windshield Wiper Motor Bolts 12.7-17.3 Nm Rear Window Wiper Motor Screws 9-12 Nm Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications > Page 11552 Wiper Motor Linkage: Service and Repair REMOVAL NOTE: The windshield wiper pivot arms must be in the highest position to remove them. 1. Turn the ignition switch to the on position. 2. Turn the windshield wiper on. 3. Stop the windshield wiper pivot arms at the highest position by turning the ignition switch off. 4. Remove the windshield wiper pivot arm. 1 Remove the pivot arm nut cover. 2 Remove the nut. 3 Remove the windshield wiper pivot arm. 5. Raise and support the hood. 6. Remove the cowl grille seal. NOTE: The two cowl grilles overlap at the center. The LH cowl grille must be removed first. 7. Remove the LH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the LH cowl grille. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications > Page 11553 8. Remove the RH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the RH cowl grille. 9. Remove the mounting arm and pivot shaft. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the mounting arm and pivot shaft. INSTALLATION Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications > Page 11554 1. To install, reverse the removal procedure. NOTE: Adjust the pivot arms. For additional information, refer to Wiper Blade and Pivot Arm Adjustment-Windshield. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Timer > Component Information > Testing and Inspection Wiper Motor Timer: Testing and Inspection Testing and Inspection For further information regarding the diagnosis of this component and the system that it is a part of, please refer to Wiper and Washer Systems; Testing and Inspection. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay Wiper Relay: Locations Wiper High/Low Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 11562 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 11563 Wiper Relay: Locations Wiper Run/Park Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 11564 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 11565 Wiper Relay: Locations Rear Wiper Up Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 11566 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 11567 Wiper Relay: Locations Rear Wiper Down Relay Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 11568 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Wiper High/Low Relay Wiper Relay: Testing and Inspection Wiper High/Low Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Wiper High/Low Relay > Page 11571 Wiper Relay: Testing and Inspection Wiper Run/Park Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Wiper High/Low Relay > Page 11572 Wiper Relay: Testing and Inspection Rear Wiper Up Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection > Wiper High/Low Relay > Page 11573 Wiper Relay: Testing and Inspection Rear Wiper Down Relay Console Blower Relay Component Testing Procedure Terminals Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams Wiper Switch: Diagrams Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 11577 Wiper Switch: Description and Operation The steering column switches consist of the: ^ multifunction switch, which controls the: ^ turn signal. ^ hazard flasher. ^ windshield wiper/washer. ^ rear wiper/washer. ^ headlamp dimmer/flash-to-pass. ^ ignition switch. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection Wiper Switch: Testing and Inspection Initial Inspection 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11580 Wiper Switch: Testing and Inspection Generic Electronic Module (GEM) DTC Index B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11581 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11582 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11583 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11584 P1836-P1891 Part 5 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11585 Wiper Switch: Testing and Inspection Component Tests Multifunction Switch Tests Component Testing Procedure Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11586 Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11587 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11588 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11589 Wiper Switch: Testing and Inspection GEM Active Command Index Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11590 Wiper Switch: Testing and Inspection Initial Inspection 1. Verify the customer concern by operating the multifunction or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: ^ check that the program card is properly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Perform the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Module Communications Network. ^ NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and perform self-test diagnostics for the GEM. 6. If the DTCs retrieved arc related to the concern, go to the Generic Electronic Module (GEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. Generic Electronic Module (GEM) DTC Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11591 B1240-B1347 Part 1 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11592 B1349-B1456 Part 2 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11593 B1458-B1894 Part 3 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11594 B2105-B2106 / C1107 / P0500-P1834 Part 4 of 5 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11595 P1836-P1891 Part 5 of 5 Component Tests Multifunction Switch Tests Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11596 Component Testing Procedure Component Testing Procedure Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11597 Component Testing Procedure Terminals Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11598 Schematic Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11599 Schematic GEM Active Command Index Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11600 Part 1 of 2 Part 2 of 2 Generic Electronic Module (GEM) PID Index Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11601 Part 2 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11602 Part 3 of 3 Test A: No Communication With the Module-GEM Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11603 Part 1 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11604 Part 2 of 3 Part 3 of 3 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11605 Test C: the Ignition Switch Is Inoperative Part 1 of 2 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11606 Test E: No Power In Run Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11607 Part 2 of 2 Test F: No Power In Start Part 1 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Initial Inspection > Page 11608 Part 2 of 2 Ford Expedition 4wd Workshop Manual (V8-5.4L SOHC VIN L (2000)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 11609 Wiper Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 3. Twist the tilt wheel handle and shank and remove. 4. Note: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover.